Crash management system for a vehicle and a method for producing the same

A crash management system for a vehicle, the crash management system comprising:

• a cross member;
• and
• two crash absorbing components,
• wherein the cross member and at least one crash absorbing component of the two crash absorbing components constitute a single extruded profile, the single extruded profile comprising at least two profile chambers which extend in a longitudinal direction of the single extruded profile,
• wherein the cross member comprises at least one first profile chamber of the at least two profile chambers of the single extruded profile,
• wherein the at least one crash absorbing component is configured from the single extruded profile in one piece and of the same material and comprises at least two profile segments which are pre-cut and bent from the single extruded profile, each of the at least two profile segments comprising a section of at least one second profile chamber of the at least two profile chambers bent in a backward direction,
• wherein the at least two profile segments remain connected with opposite sides of a base area, and
• wherein the base area is a section of the at least one second profile chamber that comprises a part of the at least one crash absorbing component that is connected to the at least one first profile chamber of the cross member, so that the at least one crash absorbing component comprises the at least two profile segments which are at least two neighboring profile segments arranged next to each other in a longitudinal direction of the cross member and extending transverse to the longitudinal direction of the cross member.

A method of producing a crash management system for a vehicle comprising a cross member and two crash absorbing components, the method comprising:

• pre-cutting a single extruded profile, which comprises at least two profile chambers in a longitudinal direction of the single extruded profile, to form pre-cut profile segments, wherein the pre-cut profile segments comprise at least one profile chamber of the at least two profile chambers and remain attached to a portion of the single extruded profile which comprises a base area of a respective crash absorbing component to be formed, wherein the pre-cut profile segments extend in the longitudinal direction of the single extruded profile starting on opposite sides of the base area;
• forming the cross member by curving free end sections of the single extruded profile;
• and
• forming at least one crash absorbing component of the two crash absorbing components by bending the pre-cut profile segments away from the cross member in a backward direction and subsequently pressing the pre-cut profile segments together in a longitudinal direction of the cross member, so that the pre-cut profile segments are arranged next to each other in the longitudinal direction of the cross member and extend transverse to the longitudinal direction of the cross member.