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An energy-absorbing crush tower for a vehicle bumper system includes a tube made of a continuous contiguous material, such as a heat-treatable steel. The tube has first and second ring sections connected by an interconnecting section. The first ring section is heat-treated to a high material strengt

An energy-absorbing crush tower for a vehicle bumper system includes a tube made of a continuous contiguous material, such as a heat-treatable steel. The tube has first and second ring sections connected by an interconnecting section. The first ring section is heat-treated to a high material strength, such as about 120 KSI tensile strength, which is substantially higher than the second ring section, which is kept at about 60 KSI tensile strength. The interconnecting section has a frustoconically-shaped portion forming a ramp. By this arrangement, upon the bumper system receiving an end impact parallel a length of the tube, the first and second ring sections telescopingly collapse with a predictable and consistent multi-phase deformation sequence where a third ring section forms between the first and second ring sections. A method related to the above is also disclosed and claimed.

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An energy-absorbing crush tower for a vehicle bumper system includes a tube made of a continuous contiguous material, such as a heat-treatable steel. The tube has first and second ring sections connected by an interconnecting section. The first ring section is heat-treated to a high material strengt

An energy-absorbing crush tower for a vehicle bumper system includes a tube made of a continuous contiguous material, such as a heat-treatable steel. The tube has first and second ring sections connected by an interconnecting section. The first ring section is heat-treated to a high material strength, such as about 120 KSI tensile strength, which is substantially higher than the second ring section, which is kept at about 60 KSI tensile strength. The interconnecting section has a frustoconically-shaped portion forming a ramp. By this arrangement, upon the bumper system receiving an end impact parallel a length of the tube, the first and second ring sections telescopingly collapse with a predictable and consistent multi-phase deformation sequence where a third ring section forms between the first and second ring sections. A method related to the above is also disclosed and claimed. 00, Shipman et al., 280/301; US-4241933, 19801200, Gratza et al., 180/219; US-4270798, 19810600, Harder, Jr., 297/411.31; US-4417746, 19831100, Baron, 280/301; US-4494764, 19850100, Kelley, 280/293; US-4690420, 19870900, Belka, 280/304.1; US-5282395, 19940200, LaPointe et al., 297/362; US-5401045, 19950300, Foerster et al., 280/250.1; US-5979269, 19991100, Su-Chen, 280/291; US-6142499, 20001100, Hsieh et al., 180/219 pper roll and the lower roll.