Fascia energy absorber, bumper system and process

The present invention provides for various embodiments of a unitary fascia energy absorber including an aesthetic appearance while also providing improved energy management. In one embodiment the fascia energy absorber includes an outer member and an inner member joined together. The inner member has a base including a plurality of crush lobes and at least one of the plurality of crush lobes includes 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. The plurality of crush lobes are spaced apart from one another and separated by a portion of the base. In another 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.

FIELD OF THE INVENTION

The present invention relates to an energy absorber for use in a bumper system and the process of making the energy absorber. More specifically, the present invention relates to a unitary fascia energy absorber for absorption of impact in a bumper system for the exterior of vehicles and a process of making the fascia energy absorber.

BACKGROUND OF THE INVENTION

The use of structures for absorbing energy in vehicles is known. Bumper systems typically extend widthwise, or transverse, across the front and rear of a vehicle and are mounted to rails that extend in a lengthwise direction. Many bumper assemblies for an automotive vehicle include a bumper beam and an injection molded energy absorber secured to the bumper beam. The bumper system generally further includes an energy absorber along the surface of the bumper and also a fascia for covering the energy absorber.

Beneficial energy absorbing bumper systems achieve high efficiency by building load quickly to just under the load limit of the rails and maintain that load constant until the impact energy has been dissipated. Energy absorbing systems attempt to reduce vehicle damage as a result of a collision by managing impact energy absorption. Bumper system impact requirements are set forth by United States Federal Motor Vehicle Safety Standards (US FMVSS), Canadian Motor Vehicle Safety Standards (CMVSS), European EC E42 consumer legislation, EuroNCAP pedestrian protection requirements, Allianz impact requirements and Asian Pedestrian Protection for lower and upper legs. In addition, the Insurance Institute for Higher Safety (IIHS) has developed different barrier test protocols on both front and rear bumper systems. These requirements must be met for the various design criteria set forth for each of the various automotive platforms and car models.

Past vehicle design trends called for streamlined fascias for a given vehicle platform and designs provided plenty of space between the fascia and the bumper beam for design of effective energy absorbers. However, current trends in bumper system designs allow consumers to have substantially more customized options. That is, for example, different styles of fascias are being designed for many more car models. The design of unique fascias results in relatively low volume manufacturing for each specific car build and tooling costs for injection molding the parts become prohibitive.

Another problem is that current designs have less space, or packaging space, in which energy absorbers can effectively meet the impact and safety requirements. Known energy absorber structures include, for example, foamed plastic materials, plastic ribbed structures, such as polypropylene honeycomb, and deformable hollow bodies. These current structures are expensive and/or do not meet the performance requirements.

SUMMARY OF THE INVENTION

The present invention, according to an embodiment of the present invention provides for a unitary fascia energy absorber including an outer member and an inner member joined together. In one embodiment, the inner member includes a base including a plurality of crush lobes. Each of the plurality of crush lobes includes 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. The plurality of crush lobes are spaced apart from one another and separated by a portion of the base. The unitary structure allows for more efficient use of space while managing energy. Also, engineering thermoplastics and the superior physical properties inherent in them can provide for better impact performances at lower wall thicknesses.

In another embodiment the fascia energy absorber includes a thermoformed outer member that is joined to a thermoformed inner member. The inner member includes a base and a plurality of crush lobes and at least one of the crush lobes has a projected wall which is spaced a distance from the base and includes at least one sidewall which extends from the base to the projected wall. The thickness of the sidewall has a thickness that is at least as great as 60% the thickness of the base near the sidewall.

In another embodiment of the present invention, a process for making a fascia energy absorber includes the steps of: heating a polymer sheet and forming the polymer sheet to produce an inner member; heating a second polymer sheet and forming the second polymer sheet to produce an outer member; and joining the inner member and the outer members. The thermoformed fascia energy absorber allows for lower tooling costs, which yields greater opportunity for customized styling of the fascia.

DETAILED DESCRIPTION OF THE INVENTION

The present invention is more particularly described in the following description and examples that are intended to be illustrative only since numerous modifications and variations therein will be apparent to those skilled in the art. As used in the specification and in the claims, the singular form “a,” “an,” and “the” may include plural referents unless the context clearly dictates otherwise. Also, as used in the specification and in the claims, the term “comprising” may include the embodiments “consisting of” and “consisting essentially of.” Furthermore, all ranges disclosed herein are inclusive of the endpoints and are independently combinable.

As used herein, approximating language may be applied to modify any quantitative representation that may vary without resulting in a change in the basic function to which it is related. Accordingly, a value modified by a term or terms, such as “about” and “substantially,” may not to be limited to the precise value specified, in some cases. In at least some instances, the approximating language may correspond to the precision of an instrument for measuring the value.

The term “plurality” as used herein refers to a quantity of two or more.

The term “multi-layer” as used herein refers to at least two layers.

FIG. 1is a schematic exploded view of a bumper system10which can be connected to a vehicle, such as for example, side rails11and13that extend longitudinally along an automobile. Bumper system10includes bumper beam12, and a fascia energy absorber14, which attaches to the bumper beam12according to an embodiment of the invention. It is understood that those skilled in the art that the bumper beam12can be made of high-strength material, such as aluminum, a composite with thermal plastic resin, for example. Fascia energy absorber14can be made from one or more of a variety of polymers and blends, as will be further described. Fascia energy absorber14includes outer member16which at least partially or fully envelopes the inner member18. Inner member18includes a base20and a plurality of crush lobes, for example crush lobes22,23and24which project from base20. As shown in the example embodiment ofFIG. 1, each of the plurality of crush lobes, for example crush lobe22has a width, WCL, which can range from a portion of the transverse width, W, of the inner member18, to the entire transverse width, W, such as for example crush lobe24which extends along substantially the entire transverse width of the inner member18and fascia energy absorber14.

FIG. 2illustrates a cut-away view of fascia energy absorber14attached to bumper beam12of bumper system10attached to side rails11and13. In one embodiment, at least one of the plurality of crush lobes of inner member18includes a base, a projected wall spaced apart from the base and at least one sidewall which extends between the base and the projected wall. For example, crush lobe22has a projected wall30and at least one sidewall such as first side wall32, second side wall34, upper wall36and lower wall38which extend from base20to projected wall30. A base portion21of base20, or “strap” separates crush lobe22from crush lobe23between sidewalls34and35, respectively. Crush lobes22and23are shown having corrugated upper wall36and lower wall38; however, alternative surface patterns are contemplated as well as planar upper and lower surfaces. The outer member16can optionally include an opening or air duct to allow air flow through the fascia energy absorber14into the radiator of an automobile, for example.

FIG. 3is a cross-sectional view taken along lines3-3of bumper system10ofFIG. 2. Fascia energy absorber14has an outer member16that is at least partially curved and substantially envelopes inner member18that contacts bumper beam12. Fascia energy absorber14is orientated in a “C-shape” configuration such that base20contacts bumper beam12and projected wall30of crush lobe22contacts outer member16. The cross-section is taken at a location of the corrugation in which crush lobe22has a height, h1and which is less than height of the bumper beam12. Crush lobe22of inner member18projects a depth, d, toward the inner member18and projected surface30contacts the outer member16. Base20separates crush lobe22and crush lobe24that extends beneath bumper beam12. The depth, d, of crush lobe22and all other crush lobes described herein can range from about 25 to 75 millimeters, in another example from about 30 to about 65 millimeters, and in another embodiment from about 35 to about 50 millimeters.

FIG. 4is a cross-sectional view taken along4-4of the bumper system10ofFIG. 2. Cross section taken along a different location of a corrugated crush lobe22than shown inFIG. 3has a height, h2which is less than height h1. Whereas base20is substantially planar at the location of contact with beam12inFIG. 3, in an alternative embodiment base20can include contoured surfaces40and41which generally conform to the profile shape of bumper beam12. In this manner the fascia energy absorber14is biased against the bumper beam12in at least two directions. Contoured surfaces40and41can provide more resistance against the upper and lower walls36,38, in a direction which helps prevent them from spreading further apart when the bumper system is impacted. When load is applied to the fascia energy absorber having a substantially planar base portion20against bumper beam12inFIG. 3, the base portion slides along the bumper beam and the absorbed energy can offer a relatively low resistance. However, inFIG. 4both contact ends of the base are engaged with the bumper beam12such that the elements bend toward the bumper beam. The strain caused by the bending offers a higher resistance to intrusion by the object or impactor.

In an alternative embodiment of the present invention,FIG. 5shows a cross-sectional view of fascia energy absorber50in which the inner member and outer member can cooperate to form a closed “box-like” cross-section against the bumper beam12. Fascia energy absorber50includes inner member52and outer member16joined to one another and which abuts and/or attaches to bumper beam12. Inner member52includes base54and crush lobe56which extends from base toward bumper beam12. Crush lobe56includes a projected wall60and upper and lower walls62and64, respectively, which extend between base54and projected wall60. Projected wall60contacts bumper beam12and base54contacts outer member16and provides a surface which distributes a load upon impact to fascia energy absorber50. The box-like structure formed by the crush lobe56in conjunction with outer member16provide increased resistance to impact upon bumper system10.

Each of the upper and lower walls62and64, respectively, which extend between the projected surface60and outer member16are shown oriented at angles, α1and α2, relative to projected wall60where the angles can range from about 90 degrees to 135 degrees, in another embodiment from slightly greater than about 90 degrees to about 110 degrees relative to projected wall60. Angles, α1and α2, can be the same or different. Likewise, the angles which separate sidewalls and projected wall of the crush lobes described above inFIGS. 3 and 4and those described throughout the various embodiments described herein can be oriented at an angle, for example α1and α2relative to the projected wall of the crush lobe. Therefore, the sidewalls of the crush lobes of the inner members can be tapered for ease of removal from the tool by which it is formed.

FIG. 6shows a perspective view of inner member52of fascia energy absorber50that is a clearer view of corrugated upper wall62and lower wall64. Crush lobe56has an extended portion70of upper wall62. The upper and lower walls72and74, respectively, of extended portion70are oriented at angles, β1and β2, relative to projected wall60where the angles can be the same or different from each other, and can be the same or different from angles α1and α2, and can vary for example within the ranges described with respect to angles α1and α2.

FIG. 7is a cross-sectional view of fascia energy absorber100mounted to bumper beam12, according to another embodiment of the present invention. Fascia energy absorber100includes outer member16and inner member102. A perspective view of inner member102shown inFIG. 8illustrates base110and crush lobes112and113. Crush lobe112has projected wall120which is spaced a distance, d, from base110and upper wall122, lower wall124and side walls136and138. Projected wall120is shown in contact with outer member16and base110contacts bumper beam12. In addition, inner member102has a second set of sidewalls140and141which extend from base110and terminate at flanges142and143, respectively, which contact outer member16. Therefore, additional sidewalls140and141have a length that is substantially equal to the depth, d, of crush lobes112and113that extend between bumper beam12and outer member16.

As shown inFIGS. 7 and 8, the projected walls120and130of crush lobes112and113, respectively, as well as flanges142and143of outer walls140and141directly contact outer member16, in an alternative embodiment, the projected walls120and130of crush lobe112and113and flanges142and143can contact bumper beam12. In any of the embodiments, the crush lobes of inner member102, in combination with either outer member16or bumper beam12, form enclosed structures that allow upper walls122and lower wall124, outer walls140and141, and sidewalls136and138to collapse in a controlled manner for effective energy management.

The cross-sectional views show the design flexibility in the various profile shapes of the inner member can affect the tuning of the fascia energy absorber. In addition, the fascia energy absorber can be tuned by varying the depth and thickness of the crush lobes of the inner member and the wall thickness of the outer member, for example. Wall thicknesses of the inner member and outer member can be the same or different, and may vary along the transverse width, W, of fascia energy absorber. For example, an inner member may be thinner in locations along the transverse width, WCL, of a crush lobe where the depth, d, is greater.

The average thicknesses of the inner and outer members can vary depending upon the selected characteristics of the fascia energy absorber. The average thickness of each of the inner member and outer member can range from about 0.1 millimeters to 10 millimeters, in an alternative embodiment, from about 1 millimeter to about 7 millimeters, and in yet another embodiment from about 2 millimeters to about 5 millimeters, and all subranges therebetween.

The inner member and the outer member of the fascia energy absorber may have a thickness composed of multi-layers of different materials. For example, outer member may have a substrate layer and a coating layer, for example a polymer or paint coating which can provide Class A surface to the fascia energy absorber. The outer layer, for example can also include a top coat layer and/or one or more intermediate layers. In such case the average thickness of each of the various layers can range as indicated above, and/or may be thinner, for example, thin layers ranging from about 0.05 millimeter to about 5 millimeters, in another example, from about 0.1 millimeter to about 1.5 millimeter, and in yet another example, from about 0.2 millimeter to about 1 millimeter, and all subranges therebetween.

As mentioned above, portions of each of the inner member and outer member can be tuned by thinning of the various walls of the crush lobes. For example the inner member which has crush lobes which emanate from the base can under go up to about 60% thinning relative to the thickness of the base, depending upon the depth of the crush lobes and the various processing methods as will be further described. In one embodiment the at least one sidewall which extends from the base to the projected wall has an average thickness which is at least as great as 50% of the thickness of the base, in another embodiment, at least as great as 60% of the thickness of the base, in another embodiment from about 60% to about 99% of the thickness of the base, and in another embodiment from about 70% to about 90% the thickness of the base.

Another aspect in appropriately tuning the energy absorber of the embodiments described above is the selection of the thermoplastic resin to be employed. The outer member and the inner member of the fascia energy absorbers herein can be made of the same or different material or polymer compositions. Two material or polymer compositions can be different if their molecular structures are different, their additives are different, or both, where additives include, but are not limited to, fillers, colorants, components which enhance processing and properties, for example. Also, as mentioned, each of the inner member and outer member may be made of two or more different material compositions.

Fascia energy absorber can be made from a non-reinforced polymer, and can be made from any suitable thermoplastic polymer, thermoset polymer, and mixtures thereof. In addition, fillers or other suitable additives may be added to the polymer material to strengthen or provide elasticity to the outer member and/or the inner member of the fascia energy absorber. The resin employed may be a low modulus, medium modulus or high modulus material as needed. By carefully considering each of these variables, energy absorbers meeting the selected energy impact objectives can be manufactured. The characteristics of the material utilized to form the energy absorber include high toughness/ductility, thermally stable, high-energy absorption capacity, a good modulus-to-elongation ratio and recyclability, among other physical properties, for example.

In any of the embodiments described above, material compositions of the outer member and the inner member can be the same or different from one another. The outer member and inner member can be made from non-reinforced polymer, for example, a polymer impregnated with long-glass fiber that is then thermoformed. The outer member and the inner member can be made from any suitable thermoplastic or thermoset material. In addition, fillers or other additives may be added to the polymer to strengthen the fascia energy absorber. Suitable fillers may include fillers such as glass fiber or plastic fiber, for example. Material compositions can include, but are not limited to, polyesters, polycarbonates, polycarbonate-based copolymers; polyesters, such as, for example, amorphous polyester terephthalate (APET), poly(ethylene terephthalate) (PET), poly(propylene terephthalate), poly(butylenes terephthalate) (PBT), poly(clyclohexane dimethanol cyclohexane dicarboxylate), and glycol-modified polyethylene terepthalate (PETG); polyvinylchloride (PVC); polysulfones, including polyethersulfone (PES), and polyphenylsulfone (PPSU); poly(vinyl acetate); polyarylates; polyetherimide (PEI); polyimide; polyamide; polyestercarbonates; polyetherketone, polyurethanes, acrylonitrile-butadiene-styrene (ABS), polycarbonate, polycarbonate/ABS blend, a copolycarbonate-polyester, acrylic-styrene-acrylonitrile (ASA), acrylonitrile-(ethylene-polypropylene diamine modified)-styrene (AES), phenylene ether resins, blends of polyphenylene ether/polyamide, blends of polycarbonate/PET/PBT, polybutylene terephthalate, phenylene sulfide resins, polyvinyl chloride PVC, high impact polystyrene (HIPS), low/high density polyethylene (LDPE, HDPE), polypropylene (PP) and thermoplastic olefins (TPO), polyether imides (PEI), and blends thereof.

FIGS. 9 through 12are schematic illustrations of steps of a process for making fascia energy absorbers, for example fascia energy absorbers14,50and100described above inFIGS. 1 through 8, in accordance with an embodiment of the present invention. The process for making the fascia energy absorber according to one embodiment includes heating a first polymer sheet and forming the polymer to produce an inner member; heating a second polymer sheet and forming the polymer to produce an outer member; joining the outer member and the inner member to produce a fascia energy absorber. Twin sheet thermoforming is one example of a process that can provide high productivity because two members of the final product, for example the outer member and the inner member, are formed simultaneously within the same thermoforming apparatus. By “simultaneously” it is meant that at least a portion of the forming process is carried out at the same time for each of the members. In an alternative process, each of the members, for example the outer member and the inner member can be formed separately, either at different times or in a separate molding apparatus, or both.

FIG. 9shows a cross-sectional view of thermoforming apparatus200having tooling which includes a male mold “core”202having core surface215and a female mold “cavity”204having a cavity surface225. Male mold core202and female die cavity204typically include vent ports203and205, respectively, for vacuuming out gases, such as air, during the thermoforming process. Thermoforming apparatus200further includes clamps212and214that secure a first polymer sheet210and clamps222and224that secure second polymer sheet220. While the polymer sheets are secured in the clamps they are heated in an oven to an elevated temperature that depends upon the polymer to be formed. For example the polymer can be heated to a temperature that is within about 50° F., in another example about 25° F., and in another example within about 10° F. of the heat deflection temperature (HTD) or melt temperature of the polymer.

In another embodiment, the process optionally includes stretching the polymer sheets210,220prior to and/or during the forming step. The polymer can be stretched, for example by gravity, in which the sheets210and220sag as shown by the dotted lines211and221prior to contacting the tooling. In this step the polymer is stretched to a substantially uniform wall thickness thereby minimizing the variation of the wall thickness in the final product. In another embodiment, the process can further include “articulating” the polymer to move edges of sheet secured by the clamps to a predetermined contour pattern. For example, clamps222and224can have articulating joints that contact the polymer sheet in several locations. The articulating joints can rotate to pre-shape the polymer sheet in close conformity to the selected shape of the final product, for example, the contour of the female die cavity225. As shown, female mold cavity204has a C-shaped contour for the selected shape of outer member16(FIG. 3) of the fascia energy absorber14and mold clamps222and224can rotate to bend polymer sheet220in a C-shaped configuration prior to placing the polymer into contact with the mold cavity204.

FIG. 10shows the apparatus200when the first polymer sheet210and second polymer sheet220conforms substantially to the core surface of215to male mold core202and is a formed inner member240, and polymer sheet220conforms substantially to mold surface225of female mold cavity204and is a formed outer member250. During the thermoforming process a gas, such as air, is directed between the male mold core and female mold cavity in a direction indicated by arrows226and228through gap227and229that forms between the tool. Optionally, a vacuum pulls the gas through vacuum ports203and205and out of the male and female mold portions in direction indicated by arrows230and232. Inner member240and outer member250which remain at an elevated temperature can be joined by coming into contact with one another and joined to form a fascia energy absorber that is similar to fascia energy absorber14of theFIGS. 1-3.FIG. 11shows the male mold core202and female mold cavity204are moved farther apart from one another so that the resulting fascia energy absorber260can be ejected or removed from the mold apparatus200. The walls of the inner member, for example walls252,254, and outer members, for example walls256,258, can be tapered for ease of removal for each action from the core and the mold cavities.FIG. 12shows resulting fascia energy absorber260includes outer member250and inner member240. The inner member240includes base270and at least one crush lobe, for example crush lobe271having projected wall272that contacts outer member250and side walls274and276which extend from base270to the projected wall272.

Therefore, in the embodiment described in steps illustrated inFIGS. 9-12, a first polymer sheet is formed onto a male mold core of a tool to produce an inner member240having an external surface; the second polymer sheet is formed onto a female mold cavity of the tool to produce an outer member250having an internal surface; and the external surface of the inner member is joined to the internal surface of the outer member to produce fascia energy absorber260. The cross-sectional illustration ofFIG. 12shows that various portions of the base and/or projected walls of the crush lobe271of inner member240is attached to outer member250.

It should be appreciated that a variety of processes can be used to join the outer member and the inner members. In the example embodiments illustrated by the process steps ofFIGS. 9-12, the molten polymers of the inner member240and outer member250allow for the materials to contact one another and adhere upon cooling. In another example, the outer member and inner member may be joined by an adhesive, a solder joint, or as another example, flanges of the outer members and inner member may include an opening through which a screw or fastener can be inserted to be attached to one another, however, the use of a fastener is not necessary. Therefore, in one example embodiment the fascia energy absorber contains no fasteners.

FIGS. 13-16show schematic illustration of steps of a process for making fascia energy absorber according to another embodiment of the present invention.FIG. 13shows a cross-sectional illustration of thermoforming mold apparatus300having a male mold core301that resides in a pressure box302. Outer member303that includes a multi-layer of material layers306and307was formed while being held between clamps304and305. Pressure box302is a open cavity enclosure in which gas, for example, air is blown into at a pressure that can range from about 10 to about 100 psi for example. Air can be blown through port314in a direction indicated313and the pressure forms the contours of outer member303against the mold surface of the core301. Core301further includes a vacuum port316that allows gas to be vacuumed out of the core in a direction indicated by arrow317.

InFIG. 14, male mold core301is shown outside of pressure box302, and outer member303conforms around shoulders320and322of male mold core. Thermoformed outer member303has thermoformed neck portions328and330that are narrower than the core shoulders320and322of core301. Therefore in another embodiment of the present invention, clamps304and305pull the outer member303in an outward direction away from the core, so as to clear the thermoformed neck portions328and330of outer member303away from core shoulders320and322. Once pulled the core wall portions338and340may be free to pass by the thermoformed neck portions328and330when core301is removed or separated from outer member303by movement of the core in an upward direction as indicated by arrow320. It is beneficial that the outer member303is maintained at an elevated temperature, at least above room temperature, while the edges of outer member303are pulled away from the core301. Therefore, in one example embodiment, the process further includes ejecting at least one of the inner member, the outer member, and pulling edges of at least one of the formed polymer sheets prior to and/or during ejection.

FIG. 15is another schematic illustration of another step in the process for forming a fascia energy absorber according to an embodiment of the present invention. The formed outer member303once separated from the core301is then placed in a fixture402of theFIG. 15. Fixture402maintains the shape of the outer member and also can maintain the heat temperature of the polymer. Apparatus400also shows a cross-sectional schematic view of male core502having a polymer inner member504that has been shaped to conform to the geometric surface of core502. Core502further includes vent port503that is used suctioning air from the core502during thermoforming of inner member504. Inner member504is shaped according to a process described above with respect to outer member303as described inFIG. 13. Inner member504and outer member303are contacted and joined along various locations of the outer member303and inner member504.

In another embodiment, the process can optionally include the step of trimming the outer member303and the inner member504.FIG. 16shows the outer member303and inner member504joined to form a fascia energy absorber600having undercuts, or lips,610and612. Inwardly protruding lips610and612of outer member303can provide esthetic edges to fascia energy absorber600which can abut to other components of a bumper system and/or a vehicle.

While thermoforming is one process to make fascia energy absorber, it will be appreciated by those in ordinary skill in the art that other suitable forming techniques may be used within the scope of the present invention. For example, other processes that may be used can include injection molding, compression molding, extrusion compress, water assist, pressure molding, well molding and rotational molding for example.

In another example embodiment, the fascia energy absorber described herein can be made in stages. For example, the process for making the fascia energy absorber can have three stages within an apparatus that is triangular in shape, for example. The process can begin at a first station in which a polymer sheet is loaded unto clamps of molding thermoforming molding apparatus. The polymer sheet, or in a twin thermoforming operation two polymer sheets, can be loaded unto the clamps of the molding apparatus. Next, the apparatus can be rotated for example in an approximately 120 degrees to advance the sheet to the subsequent adjacent station of the thermoforming apparatus. Therefore, clamps and thermoplastic sheet are moved to the second position that includes an oven for heating the polymer. Then the polymer sheet can be moved to a third thermoforming station which can be equipped with a mold core or a mold cavity or both. In this third stage, the vacuum is applied and air pressure is blown to force the polymer sheet against the mold core or mold cavity.

Therefore in a continuous process, at least a portion of each of the steps of the loading, heating, forming, and joining, is carried out simultaneously. At the first station, a polymer sheet of a first material is loaded onto the clamps, at the second station the polymer is heated, at the third station a gas, for example, air, is blown against the polymer sheet to form an outer member and/or a inner member. At the third station or at an additional fourth station the outer member and the inner member are joined to produce a fascia energy absorber having an outer member of a first material composition and inner member of a second material composition which can be the same or different than the first material composition.

Also, in many continuous processes, the ejection stage of the process is the shortest. Therefore, in the process of the present invention described above the ejection station, at which product is ejected from the mold is the same station as the loading station, at which polymer sheet is loaded for the next cycle. That is, the fascia energy absorber produced from the previous cycle can be ejected and new polymer sheet can be loaded to start the next cycle, at the “eject-load station,” in less time than it takes to complete the heating or the forming steps of the second and third stages, respectfully. As one example, the combined ejecting and loading time is equal to or less than the time for each of the heating and forming steps.

Therefore, in one embodiment the process includes: 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.

While embodiments of the invention have been described, it would be understood by those skilled in the art that various changes may be made and equivalence may be substituted for the energy absorber or system thereof without departing from the scope of the invention. For example, although example embodiments discussed above pertain to vehicles, it should be understood that several other applications may find use of the fascia energy absorber. Also, several different polymers may be used. Many modifications may be made to adapt a particular situation of material to the teachings of the invention without departing from the essential scope thereof. Therefore, it is intended that the invention not be limited to particular embodiments, but that the invention will include all embodiments falling within the scope of the pending claims.