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An energy-absorbing system includes two formed and sealed components bonded together to form crush boxes that entrap air for controlled distribution during an impact, and an activator system adapted to extend the crush boxes in the event of a vehicle crash. Channels interconnect the crush boxes for

An energy-absorbing system includes two formed and sealed components bonded together to form crush boxes that entrap air for controlled distribution during an impact, and an activator system adapted to extend the crush boxes in the event of a vehicle crash. Channels interconnect the crush boxes for optimal control of lateral flow of air for lateral energy distribution. The components can be thermoformed, injection molded, or otherwise formed. By this arrangement, the crush boxes provide a first level of static energy absorption when impacted in an undeployed state such that energy is absorbed at a first rate and stroke. Also, the crush boxes can be extended to provide a second level of static energy absorption when impacted in a vehicle crash (i.e., the activator system is energized and the crush boxes extended or “deployed”) such that energy is absorbed at a one or more different rates and strokes.

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The embodiments of the invention in which an exclusive property or privilege is claimed are defined as follows: 1. An energy-absorbing system for a passenger compartment of a vehicle, the energy-absorbing system being adapted to cover an interior surface of a structural component and adapted to pro

The embodiments of the invention in which an exclusive property or privilege is claimed are defined as follows: 1. An energy-absorbing system for a passenger compartment of a vehicle, the energy-absorbing system being adapted to cover an interior surface of a structural component and adapted to provide energy absorption for reducing passenger injury during a vehicle crash where the passenger is thrown against and impacts the interior surface, comprising: an energy-absorbing component shaped to cover at least a portion of the interior surface of the structural component and defining a thickness extending generally perpendicular to the interior surface, the energy-absorbing component having crush box structures constructed to crush along a shorter first crush stroke distance and absorb energy based on a first energy absorbing profile when impacted in a direction generally parallel the thickness; and an activator connected to the crush box structures and constructed to telescopingly expand the crush box structures to an increased thickness to thus crush along a longer second crush stroke distance and absorb energy based on a second energy absorbing profile when a vehicle impact is sensed, the first and second energy absorbing profiles being different shapes and absorbing energy at different rates. 2. The system defined in claim 1, wherein the crush box structure includes a plurality of spaced-apart crush boxes. 3. The system defined in claim 1, including a programmable controller operably connected to the activator and to an air source for expanding the crush box structures. 4. The energy-absorbing system defined in claim 1, wherein the energy-absorbing component includes a knee bolster. 5. An energy-absorbing system for covering structural components in a passenger compartment of a vehicle, comprising: first and second components including adjacent polymeric sheets, each defining a plurality of crush boxes that inter-fit to define air-trapping chambers, at least some of the crush boxes having an offset wall facilitating extension, the crush boxes each defining a thickness and being constructed to crush and absorb energy when impacted in a direction generally parallel the thickness. 6. The energy-absorbing system defined in claim 5, including an activator connected to at least some of the crush boxes to expand the at least some crush boxes to an increased thickness when a vehicle impact is sensed. 7. An energy-absorbing system comprising: a sensor for sensing severity of vehicle impact; an energy absorber made primarily of polymeric material and having internal structure that provides a first level of impact resistance over a first crush stroke distance; and an activator and a controller operably connected to each other and to the sensor and to the internal structure for variably controlling energy absorption by the internal structure to provide a variable level of impact resistance including at least two additional different levels of impact resistance. 8. The energy-absorbing system defined in claim 7, wherein the controller includes a valve for controlling air flow in a passageway connected to the internal structure. 9. The energy-absorbing system defined in claim 8, wherein the valve controls air outflow from the internal structures. 10. The energy-absorbing system defined in claim 8, wherein the valve controls in-flow of air to the internal structure. 11. The energy-absorbing system defined in claim 8, wherein the internal structure includes spaced-apart crush boxes. 12. A system for absorbing energy in a vehicle comprising: a vehicle including a body defining a passenger compartment with occupant-related energy-absorbing members and also including front and rear bumper systems with bumper-related energy-absorbing members, the occupant-related energy absorbing members and the bumper-related energy absorbing members each having respective energy-absorbing profiles with known rates of energy absorption during respective crush strokes; sensors on the vehicle for sensing a type or severity of a vehicle impact and for generating a signal related to the type or severity of vehicle impact; and a controller operably connected to the sensors and also to the occupant-related energy absorbing members and to the bumper-related energy-absorbing members; the controller being configured to receive the signal and to cause the occupant-related energy-absorbing members and to cause the bumper-related energy absorbing members to vary from the respective energy-absorbing profiles by changing at least one of the rate of energy absorption and a length of the crush stroke. 13. The system defined in claim 12, wherein the occupant-related energy-absorbing members include a knee bolster. 14. The system defined in claim 12, wherein the controller includes a valve controlling air outflow from one of the occupant-related energy absorbing members. 15. An energy-absorbing system for a passenger compartment of a vehicle, the energy-absorbing system being adapted to cover an interior surface of a structural component and adapted to provide energy absorption for reducing passenger injury during a vehicle crash where the passenger is thrown against and impacts the interior surface, comprising: an energy-absorbing component shaped to cover at least a portion of the interior surface of the structural component and defining a thickness extending generally perpendicular to the interior surface, the energy-absorbing component having crush box structures constructed to crush along a crush stroke distance and absorb energy based on an energy-absorbing profile when impacted in a direction generally parallel the thickness; and a valve connected to the crush box structures and constructed to control one of in-flow and out-flow of fluid to the crush box structures; and a device for operating the valve based on a severity of vehicle crash to control flow of the fluid and therefore change the energy-absorbing profile of the crush box structures based on the type of vehicle crash. 16. The energy-absorbing system defined in claim 15, wherein the valve controls air outflow. 17. The energy-absorbing system defined in claim 15, wherein the valve controls in-flow of air to the crush box structures. 18. The energy-absorbing system defined in claim 15, wherein the crush box structures include a plurality of spaced-apart crush boxes connected by a sheet of polymeric material. 19. The energy-absorbing system defined in claim 15, wherein the energy-absorbing component includes a knee bolster. 20. A system for absorbing energy in a vehicle comprising: a vehicle including a body defining a passenger compartment with at least one energy-absorbing member positioned within the passenger compartment, the energy-absorbing member being adjustable in energy-absorbing capability; a sensor on the vehicle for sensing a vehicle impact and for generating a signal related to the vehicle impact; and a control operably connected to the sensor and also to the energy-absorbing member; the control being configured to receive the signal and to cause the energy-absorbing member to adjust the energy-absorbing member in correspondence to a type of impact being experienced by the vehicle. 21. The system defined in claim 20, wherein the energy-absorbing member includes a knee bolster. 22. The system defined in claim 20, wherein the control includes a valve for controlling air flow in a passageway connected to the energy-absorbing member. 23. A variable energy management system for absorbing energy during a vehicle crash comprising: a vehicle including a body defining a passenger compartment with at least one first deployable energy-absorbing member positioned within the passenger compartment and including a bumper system with at least one second deployable energy-absorbing member; a sensor on the vehicle for sensing a vehicle impact and for generating at least one signal related to the vehicle impact; and a controller operably connected to the sensor and also to the first and second energy-absorbing members; the controller being configured to receive the signal and being programmed to selectively deploy one or both of the first and second energy-absorbing members in at least three different ways, the first way being to minimize injury to a pedestrian struck by the bumper system, the second way being to minimize injury to an occupant riding in the vehicle during a vehicle crash, and the third way being to minimize damage to the vehicle. 24. The system defined in claim 23, wherein the controller includes a valve for controlling fluid flow in a passageway connected to the first energy-absorbing member. 25. The system defined in claim 24, wherein the valve controls air outflow. 26. The system defined in claim 23, wherein the first energy-absorbing member includes a knee bolster. 27. A variable energy management system for absorbing energy during a vehicle crash comprising: a vehicle including a body defining a passenger compartment with at least one first deployable energy-absorbing member positioned within the passenger compartment and including a bumper system with at least one second deployable energy-absorbing member; a sensor on the vehicle for sensing a vehicle impact and for generating at least one signal related to the vehicle impact; and a controller operably connected to the sensor and also to the first and second energy-absorbing members; the controller being configured to receive the signal and being programmed to selectively deploy the first and second energy-absorbing members in ways associated with increasingly severe vehicle crashes. 28. The system defined in claim 27, wherein the controller includes a valve for controlling fluid flow in a passageway connected to the first energy-absorbing member. 29. The system defined in claim 28, wherein the valve controls air outflow. 30. The system defined in claim 27, wherein the first energy-absorbing member includes a knee bolster.