A New 5MPH Bumper System 942277

A new bumper system which provides 8 kph (5 mph) vehicle protection with superior quality, outstanding durability and high value is in production. The system includes five new technologies:
  • Hot stamped, ultra high strength front beam, 970 N/mm2 (160 KSI) which also is the #1 body structure crossmember.
  • Ultra high strength roll formed rear beam 1150 N/mm2 (190 KSI).
  • polypropylene foam isolators designed for controlled energy management
  • Thermoplastic olefin (TPO), injection molded fascias
  • Two component urethane paint for long term color, gloss and scratch resistance.
This bumper system, installed on over 100,000 vehicles so far, meets both MPV and passenger car 8 kph standards.
Consumer and insurance industry trends indicate increasing demand for Multi Purpose Vehicle (MPV) bumper systems which meet 8 kph criteria. The major competitors in the MPV market (Aerostar, Grand Caravan, Toyota Previa, GM APV's, and Mazda MPV) have either 0 kph or at best 4 kph systems. All Ford cars and most passenger cars have 8 kph bumper systems.
Consistent, high quality vehicle to vehicle exterior appearance is a must in the marketplace. Today's sophisticated consumer expects good fits and long life from the vehicle. Many current bumper systems are unable to be assembled, manufactured and delivered to meet these requirements due these typical approaches:
  • Operator dependant installation of fascias (do not locate directly to surrounding sheetmetal).
  • PGM's which locate independently to structure and do not locate the beam well.
  • Materials and paints which cannot achieve the most recent demands for high milage.
Developing a mini-van bumper system which met the performance and quality needs along with the other cost, weight, investment, timing, testing, styling, manufacturing and assembly criteria required the team to investigate new technologies. Five technologies allowed all needs and criteria to be met or exceeded. The purpose of this paper is to provide an understanding of these technologies and encourage additional applications.


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