Pelvic assembly

Abstract

The present utility model relates to a pelvic assembly. A pelvic assembly of an anthropomorphic test device includes: an outer elastomeric member formed of a first material, the outer elastomeric member defining an inner cavity and a pelvic cavity; and an elastomeric insert formed of a second material and partially positioned within the inner cavity. A structural member formed of a rigid material is partially contained within the inner cavity and exposed to the pelvic cavity, wherein the insert is coupled to the structural member and the insert is positioned between the outer elastomeric member and the structural member. The second material of the insert is different in composition or different in mechanical properties from the first material of the outer elastomeric member, and the outer elastomeric member and the insert are collectively sized and shaped to approximate compression characteristics when a human sits on the structure during a crash test simulation.

Description

Technical Field

[0001] This disclosure generally relates to an anthropomorphic testing device (ATD), and more specifically, to a pelvic assembly for an ATD, comprising a pelvic assembly having an external elastomer member and an elastomer insert. Background Technology

[0002] Automobile, aircraft, and other transportation manufacturers conduct various crash tests to measure the impact of collisions on vehicles and their occupants, and to validate vehicle safety systems. Crash tests typically use anthropomorphic testing devices (ATDs), commonly known as "crash test dummies," to estimate human injury risk and simulate the biomechanical response of the human body in a collision event. ATDs must possess the basic mechanical characteristics, dimensions, mass, joints, and joint stiffness of the target human body. Therefore, ATDs are designed to replicate the size, shape, weight distribution, and joint articulation of the human body, enabling researchers and engineers to assess injury risk and improve occupant protection strategies. Furthermore, they must possess sufficient mechanical impact response similarity and sensitivity to allow ATDs to interact with the interior of the vehicle in a human-like manner.

[0003] This disclosure relates to improvements to the pelvic assembly to more closely approximate the human-like response of the pelvic region during crash test simulations. Utility Model Content

[0004] This disclosure relates to a pelvic assembly of an anthropomorphic testing apparatus, comprising: an external elastomeric member formed of a first material defining an inner cavity and a pelvic cavity; and an elastomeric insert formed of a second material and partially positioned within the inner cavity. The pelvic assembly also includes a structural member formed of a rigid material and partially housed within the inner cavity and exposed to the pelvic cavity, wherein the elastomeric insert is coupled to the structural member and positioned between the external elastomeric member and the structural member. The second material of the elastomeric insert differs in composition from the first material of the external elastomeric member, or differs in mechanical properties from the first material of the external elastomeric member, and the external elastomeric member and the elastomeric insert are jointly sized and shaped to approximate the compressive properties of a human sitting on the structure during crash test simulations.

[0005] This disclosure also provides a corresponding method for forming a pelvic component.

[0006] This disclosure also provides a method for forming a pelvic assembly for an anthropomorphic testing device, the method comprising: providing a structural member formed of a rigid material; adhering an elastomeric insert to an outer surface of a portion of the structural member; introducing the structural member with the adhering elastomeric insert into a mold; and molding an external elastomeric member within the mold, wherein the external elastomeric member forms a pelvic cavity and an inner cavity, wherein the structural member is partially housed within the inner cavity and exposed to the pelvic cavity, and wherein the elastomeric insert is positioned within the inner cavity between the external elastomeric member and the structural member, wherein the external elastomeric member is formed of a first material, and wherein the elastomeric insert is formed of a second material, wherein the second material of the elastomeric insert is different in composition or in mechanical properties from the first material of the external elastomeric member, and wherein the external elastomeric member and the elastomeric insert are jointly sized and shaped to approximate the compression characteristics of a human sitting on the structure during crash test simulations.

[0007] According to the above method, in the step of molding the external elastomer component in the mold, the hip region of the external elastomer component is formed with one or more rearward openings, wherein the one or more rearward openings are configured to allow access to the structural component partially accommodated in the cavity.

[0008] This disclosure also provides a system for designing a pelvic assembly for anthropomorphic testing equipment. The system includes a computer having at least one processor, the processor including a memory. The system also includes a first software application stored in the memory and configured to create a virtual pelvic assembly. The virtual pelvic assembly includes: a virtual external elastomer member virtually formed of a first virtual material, the virtual external elastomer member defining a virtual cavity and a virtual pelvic cavity; and a virtual elastomer insert virtually formed of a second virtual material and virtually partially positioned within the virtual cavity. The virtual pelvic assembly also includes a virtual structural member virtually formed of a rigid virtual material and virtually partially accommodated within the virtual cavity, wherein the virtual elastomer insert is virtually coupled to the virtual structural member and positioned between the virtual external elastomer member and the virtual structural member. The second virtual material of the virtual elastomer insert is different in composition from the first virtual material of the virtual external elastomer component, or different in mechanical properties from the first virtual material of the virtual external elastomer component, and the virtual external elastomer component and the virtual elastomer insert are virtually sized and shaped together to approximate the compression characteristics of a human sitting on the structure during a crash test simulation. Attached Figure Description

[0009] Other features and advantages of this disclosure will become clearer and better understood when read in conjunction with the accompanying drawings.

[0010] Figure 1 This is a perspective view of one embodiment of the pelvic assembly, showing its operational relationship with an anthropomorphic testing device.

[0011] Figure 2 yes Figure 1 A partial front perspective view, which includes a portion of the head assembly, neck assembly, and spine assembly.

[0012] Figure 3 yes Figure 1 An exploded view of the pelvic components.

[0013] Figure 4 yes Figure 1 Another exploded view of the pelvic components, in which the parts are arranged vertically relative to each other.

[0014] Figure 5A yes Figure 1 A posterior cross-sectional view of the pelvic components, with the spinal components removed from the pelvic cavity.

[0015] Figure 5B yes Figure 1 Another rear view and partial cross-sectional view of the pelvic assembly, in which the spinal assembly is removed from the pelvic cavity.

[0016] Figure 5C yes Figure 5B Another rear-view and partial cross-sectional view, its cut position is compared to Figure 5B The middle is further forward.

[0017] Figure 5D yes Figure 5B Another rear-view and partial cross-sectional view, its cut position is compared to Figure 5B and Figure 5C The middle is further forward.

[0018] Figure 6 It is a perspective view of the structural member and the elastomer insert connected together, and of the external elastomer member, wherein the structural member and the elastomer insert are removed from the external elastomer member.

[0019] Figure 7 This is the main view of the pelvic components.

[0020] Figure 8 This is a rear view of the pelvic components.

[0021] Figure 9 This is a bottom view of the pelvic components.

[0022] Figure 10 This is a left-side view of the pelvic components.

[0023] Figure 11 This is a perspective view of the inserts of the pelvic assembly.

[0024] Figure 12 This is the main view of the insert for the pelvic assembly.

[0025] Figure 13 This is a rear view of the insert for the pelvic assembly.

[0026] Figure 14 This is a bottom view of the insert of the pelvic assembly.

[0027] Figure 15 This is a perspective view of the structural components of the pelvic assembly.

[0028] Figure 16 This is a top view of the structural components of the pelvic assembly.

[0029] Figure 17 This is a bottom view of the structural components of the pelvic assembly.

[0030] Figure 18 This is a rear view of the structural components of the pelvic assembly.

[0031] Figure 19 This is a front view of the structural components of the pelvic assembly.

[0032] Figure 20 This is another exploded front view of the pelvic assembly, where the components are arranged vertically.

[0033] Figure 21 yes Figure 20 Rear view.

[0034] Figure 22 yes Figure 20 The left-side view.

[0035] Figure 23 yes Figure 20 The rear perspective view.

[0036] Figure 24 This is a schematic diagram of a system for creating and evaluating virtual anthropomorphic test equipment that includes pelvic components.

[0037] Figures 25A-25E yes Figure 1 Various virtual perspective views of the inserts of the pelvic components.

[0038] Figures 26A-26E yes Figure 1 Various virtual perspective views of the structural components of the pelvic assembly.

[0039] Figures 27A-27I yes Figure 1Various virtual perspective views of the external elastomeric components, elastomeric inserts, and structural components of the pelvic assembly.

[0040] Figures 28A-28C yes Figure 1 A virtual perspective view of the external elastomeric components, elastomeric inserts, and structural components of the pelvic assembly.

[0041] Figures 29A-29B yes Figure 1 A virtual perspective view of the external elastomeric components, elastomeric inserts, and structural components of the pelvic assembly, wherein the elastomeric inserts are connected to the structural components. Detailed Implementation

[0042] This application relates to a pelvic assembly of an anthropomorphic testing device (ATD) whose size and shape are designed to approximate the compressive characteristics of a human sitting on the structure during crash test simulations. Simultaneously, this application relates to a pelvic assembly of an ATD including easily accessible electronic components for inspection, repair, or replacement.

[0043] Refer to the accompanying drawings and specifically to... Figure 1 and Figure 2 An embodiment of an anthropomorphic testing device (ATD) – also known as a crash test dummy – is generally designated 12. The ATD 12 shown is of female type and is depicted in a seated position. As will be apparent from the detailed description below, the ATD 12 shown is intended for testing or otherwise evaluating the performance of vehicle interior and restraint systems for pre-adult and post-adult occupants, and more specifically for rear-end impact testing. It will be understood that this invention can be used with any suitable type of ATD for any type of crash test. It should also be noted that the range of motion, center of gravity, and segmental mass are simulated for those human subjects defined by anthropomorphic data.

[0044] Typically, the anthropomorphic testing device 12 includes a head assembly 13 and a neck assembly 14, with the neck assembly 14 having an upper end attached to the head assembly. The ATD 12 includes a spine assembly 15, which has an upper end attached to the neck assembly 14. The spine assembly 15 has a lower end 28 extending into the pelvic region of the ATD 12, which is secured to a structural member 100 housed within the pelvic assembly 22, as further explained below.

[0045] The anthropomorphic testing device 12 also includes a torso interface pin 16 connected to the spine assembly 15. The ATD 12 also has a pair of arm assemblies, including a right arm assembly 18 and a left arm assembly 20, which are attached to the ATD 12. The ATD 12 includes a pelvic assembly 22. The ATD 12 also includes a right leg assembly 24 and a left leg assembly 26, which are attached to the pelvic assembly 22. It should be noted that the various components of the ATD 12 are covered with polyurethane, vinyl, or silicone skin, or combinations thereof, such as muscle and skin assemblies (not shown), to improve connection with the skeleton of the ATD 12.

[0046] like Figures 3-23 As shown in the optimal configuration, the lower end 28 of the lumbar spine portion of the spinal assembly 15 is attached to the pelvic assembly 22. (Reference) Figure 1 and Figure 2 The ATD 12 also includes a right leg assembly 24 and a left leg assembly 26, which are also attached to the pelvic assembly 22.

[0047] The pelvic assembly 22 includes a hollow pelvic member 40 that defines an inner cavity 65, which allows for the inclusion of a structural member 100, shown herein as a pelvic structural member 100, designed to mimic the human pelvic bones to support the abdomen from below. The structural member 100 is preferably formed of a rigid material such as metal. The structural member 100 is positioned within the pelvic assembly 22, exposing it to a pelvic cavity 66, sometimes alternatively referred to as an exposed pelvic cavity 66 or exposed chamber 66, which is also defined by the pelvic member 40. When the lower end 28 of the spinal assembly 15 is attached to the structural member 100, the pelvic cavity 66 also partially accommodates the lower end 28 of the spinal assembly 15, as further described below. In some cases, the structural member 100 may be coupled to one or more further support structures 120 (i.e., additional support structures 120). Figure 2 The image shows a pair of thigh support structures 120 (also referred to as simulated femurs 120) within the cavity 65. The pelvic assembly 22 also includes electronic components that are positioned within the pelvic assembly 22 when the anthropomorphic testing device 12 is fully assembled and the spine assembly 15 is mounted to the structural member 100, as explained further below.

[0048] The pelvic component 40 includes an abdominal region 50 and a pair of thigh regions 52, 54 (i.e., right thigh region 52 and left thigh region 54) extending from the abdominal region 50. The pelvic component 40 also includes a hip region 56 that connects the abdominal region 50 to the pair of thigh regions, wherein the hip region 56 is positioned below the abdominal region 50 and behind each of the thigh regions 52, 54. When the anthropomorphic test device 12 is positioned on a surface, the hip region 56 of the pelvic component 40 is positioned adjacent to and preferably in contact with said surface. In crash test simulations, the pelvic component 40 may be positioned on any other type of surface used in evaluating the anthropomorphic test device 12, such as a vehicle seat, a chair, or any other type of structure having a surface capable of receiving the anthropomorphic test device 12 placed thereon. As used herein, a surface may refer to any of the types of surfaces described above, and particularly to the surface on which the anthropomorphic test device 12 is placed (e.g., in a seated position) for subsequent testing (e.g., crash testing).

[0049] The hip region 56 can be compressed / collapsed (i.e. simulated hip compression) to approximate the weight force exerted by a human sitting on the surface prior to a crash test. This allows the anthropomorphic testing device 12 to more closely simulate the performance of the human pelvic components under impact conditions associated with a collision, such as a collision while sitting on a vehicle seat in a vehicle like a car.

[0050] The pelvic member 40 includes an external elastomer member 60 that is typically, but optionally, covered with skin 62. In use, skin 62 may enclose the external elastomer member 60, and thus skin 62 defines a cavity portion 64 that receives the external elastomer member 60. Skin 62 can be subdivided into an inner skin portion 62A and an outer skin portion 62B, the inner skin portion 62A further defining an inner cavity 65 of the pelvic member 40, and the outer skin portion 62B contacting a surface (such as a vehicle seat) when the ATD 12 is positioned for evaluation during crash test simulations. For ease of description below, the external elastomer member 60 may be simply referred to without mentioning skin 62, even if skin 62 is present. The external elastomer member 60 defines both the inner cavity 65 of the structural member 100 and a pelvic cavity 66 that partially receives the lower end 28 of the spinal member 15 (when the spinal member 15 is mounted to the structural member 100). One or more openings 72 may be provided, extending through both the skin 62 and the external elastomer member 60, wherein the openings 72 are formed during the manufacture of the external elastomer member 60 by a molding process (such as molding), or may be formed after molding by a process such as drilling.

[0051] The external elastomer component 60 is formed of a first material (preferably an elastic material, such as a thermoplastic or thermosetting elastic material). An exemplary elastic material used in the external elastomer component 60 is polyurethane. The skin 62 covering the external elastomer component 60 (in use) can be a vinyl skin, a polyurethane skin, or another elastic material.

[0052] The pelvic component 40 also includes an elastomeric insert 80, which is at least partially housed in the cavity 65 of the outer elastomeric component 60 and is coupled to and preferably adhered to the structural component 100 and optionally also coupled to the additional support structure 120.

[0053] The elastomeric insert 80 may be formed of the same or different material as the outer elastomeric member 60. However, preferably, the elastomeric insert 80 is in the form of a closed-cell or open-cell foam and is manufactured using a foam molding process. The elastomeric insert 80 may also define one or more openings 82 through which it passes, the openings 82 being formed during the manufacture of the elastomeric insert by a molding process (such as molding), or may be formed after molding by a process such as drilling.

[0054] More specifically, the external elastomeric member 60, with or without skin 62, and the elastomeric insert 80 are respectively shaped and sized such that the center of gravity of the pelvic assembly 22 (in combination with structural member 100, additional support structure 120, and any electronic components 230) approximates the center of gravity exhibited by a human in the pelvic region corresponding to the pelvic assembly 22, and also approximates the compression characteristics of a human sitting in a car seat before and during crash test simulations. Compared to a pelvic assembly without these features, the compression of the pelvic assembly 40 more closely simulates the corresponding hip compression of a human sitting on the same surface.

[0055] In some embodiments, the mass of the external elastomer member 60 (with or without skin 62) may be a range of 40 to 90 percent of the total mass of the pelvic assembly 22 (including the external elastomer member 60, the elastomer insert 80, the structural support member 100, and any counterweights optionally included in the pelvic assembly 22, ranging from 0 to 10 percent by mass). In conjunction with this, the volume of the external elastomer member 60 (with or without skin 62) may be a range of 40 to 90 percent of the total volume of the pelvic assembly 22 (including the external elastomer member 60, the elastomer insert 80, the structural support member 100, and any counterweights optionally included in the pelvic assembly 22, ranging from 0 to 10 percent by volume).

[0056] In some embodiments, the mass of the elastomeric insert 80 may be a range of 10 to 70 percent of the total mass of the pelvic assembly 22 (including the external elastomeric member 60, the elastomeric insert 80, the structural support member 100, and any counterweights included in the pelvic assembly 22, ranging from 0 to 10 percent by mass). In conjunction with this, the volume of the elastomeric insert 80 may be a range of 10 to 70 percent of the total volume of the pelvic assembly 22 (including the external elastomeric member 60, the elastomeric insert 80, the structural support member 100, and any counterweights included in the pelvic assembly 22, ranging from 0 to 10 percent by volume).

[0057] Furthermore, the mass of structural member 100 can be based on the total mass of pelvic assembly 22 (including external elastomer member 60, elastomer insert 80, structural support member 100, and any counterweights included in pelvic assembly 22, ranging from 0 to 10% by mass) within a range from greater than 0 to 60% by mass. In conjunction with this, structural member 100 can be based on the total volume of pelvic assembly 22 (including external elastomer member 60, elastomer insert 80, structural support member 100, and any counterweights included in pelvic assembly 22, ranging from 0 to 10% by volume) within a range from greater than 0 to 60% by mass.

[0058] When the anthropomorphic testing device 12 is positioned on the surface, the force exerted on the surface by the weight of the anthropomorphic testing device 12 through the hip region 56 of the pelvic member 40 causes the external elastomer member 60 and the elastomer insert 80 to compress.

[0059] When the anthropomorphic testing device 12 is not seated on the surface, or when the pelvic component 40 is removed from the surface or otherwise not loaded onto the object on which it is seated by its own weight or other forms of loading force, the resilience of the external elastomer component 60 and the elastomer insert 80 allows the pelvic component 40 to substantially return to its normal shape (i.e., expand) when not seated on the surface.

[0060] In some embodiments, when the combination of the external elastomeric member 60 with skin 62 and the elastomeric insert 80 of ATD 12 described herein is tested using a conventional pendulum test by measuring the force of the probe using an impactor, the impact test is performed by impacting the hip region 56 of the pelvic member 40 with a 20kg ballistic pendulum impactor at an impact velocity of 2.0 m / s, and the measured impact force ranges from 1100N to 2300N.

[0061] In some embodiments, when the anthropomorphic test device 12 is in a fully assembled state, the anthropomorphic test device 12 also includes a number of electronic components (not shown) positioned in the pelvic assembly 22.

[0062] These electronic components can be divided into two categories. First, there are one or more electronic components (not shown), also interchangeably referred to as the first group of electronic components, which are coupled or otherwise secured to one or both of the structural member 100 or other support member 120, or otherwise positioned within the pelvic assembly 22 or secured to one or both of the structural member 100 or other support member 120. Second, there are one or more electronic components, also interchangeably referred to as the second group of electronic components (not shown), which are coupled or otherwise secured to the spinal assembly 15, for example, coupled or secured to the lower end 28 of the spinal assembly 15.

[0063] Preferably, the first set of electronic components is positioned between the outer surface 110 of the structural member 100 and the external elastomer member 40, and is housed within a portion of the cavity 66. The first set of electronic components is accessible through one or more openings 68 (or alternatively, one or more rearward openings 68) housed in the hip region 56 of the external elastomer member 60. In situations such as... Figures 5B-5D and Figure 6 In the illustrated embodiment, a single rearward opening 68 is shown that extends sequentially through an opening in the inner skin 62A adjacent to the first set of electronic components, the outer elastomer member 60, and the outer skin 62B.

[0064] In these embodiments, the cover plate 150 is positioned within the rear opening 68 and is mounted to the outer surface 110 of the structural member 100 using one or more cover plate fasteners 152 (shown as bolts 152 in the figure), such that the first set of components 210 is positioned between the outer surface 110 of the structural member 100 and the cover plate 150.

[0065] To access the first set of electronic components, cover plate fasteners 152 are disengaged from the outer surface 110 of structural member 100 to remove cover plate 150 from structural member 110. Fasteners 152 and cover plate 150 are then removed from rearward opening 68, thereby allowing access to the first set of electronic components through rearward opening 68. Notably, it is not necessary to remove the spine assembly 15 from structural member 110 to access the first set of electronic components.

[0066] The spinal assembly 15 is mounted to the structural member 100 using one or more fasteners 90 (shown as bolts 90), wherein each fastener 90 is sequentially inserted through one or more openings 70, 72 in the pelvic member 40, through a corresponding opening 111 in the structural member 100 extending between the inner surface 105 and the outer surface 110 (while engaging with the structural member 100), through a corresponding opening 112 located on the inner surface 105 of the structural member 100 or in a mounting interface defined by the inner surface 105 (while engaging with the mounting interface), and into and engages a corresponding opening in a mounting plate of the spinal assembly, which is itself attached to or integrally formed with the lower end 28 of the spinal assembly 15.

[0067] One or more openings 70 in the hip region 56 of the pelvic component 40 preferably include one or more openings 72 in the external elastomer component 60 (and in particular openings 72 extending sequentially through the outer skin 62B, the external elastomer component 60 and the inner skin 62A), and one or more openings 82 in the elastomer insert 80, wherein one opening 72 in the external elastomer component 70 is aligned with a corresponding opening 82 in the elastomer insert 80 adhered to the outer surface 110.

[0068] Alternatively, in some embodiments, the fastener 90 may be inserted through the opening 72 in the external elastomeric member 60 and directly through the opening 111 in the structural member 100 (and the opening 112 in the mounting interface 114), while engaging with the structural member 100 (and the mounting interface 114) without extending through the elastomeric insert 80 in the hip region 56.

[0069] Furthermore, in some alternative embodiments, in addition to the openings 72, 82 in the hip region 56, the fastener 90 may also be inserted through an opening (not shown) in the abdominal region 50 and / or through an opening in the thigh regions 52, 54 and aligned with openings 111, 112 and the opening in the mounting plate to mount the spine assembly 15 to the structural member 100, in a process similar to that described above. Even further still, the fastener 90 may be inserted through an opening (not shown) in the abdominal region 50 and / or through an opening in the thigh regions 52, 54, without passing through openings 72, 82 in the hip region 56, wherein the openings in the abdominal region 50 and / or through openings in the thigh regions 52, 54 are directly aligned with openings 111, 112 and the opening in the mounting plate to mount the spine assembly 15 to the structural member 100, in a process similar to that described above.

[0070] To form an ATD 12 having or not having a first set of electronic components and a second set of electronic components respectively connected to the spinal assembly 15 and / or the structural member 100, and with the spinal assembly 15 mounted to the structural member 100, the following procedure may be used.

[0071] Initially, the lower end 28 of the spinal assembly 15 has a second set of electronic components (if included) that are coupled to, fastened to, or otherwise secured to a mounting plate, which is itself coupled to or integrally formed with the lower end 28 of the spinal assembly 15. Alternatively, as an initial step in the process, the second set of electronic components and the mounting plate can be coupled, fastened, or otherwise secured to the lower end 28 of the spinal assembly 14 by conventional methods.

[0072] In addition, a structural member 100 is provided, preferably having an additional structural member 120 connected thereto, and optionally also including a mounting interface 114 connected thereto.

[0073] Next, the pelvic component 40 is formed.

[0074] As part of forming the pelvic component 40, an elastomeric insert 80 is first formed or otherwise provided. To form the elastomeric insert 80 (wherein the elastomeric insert 80 is a foam insert) according to this disclosure, a standard molding process can be employed. In this process, a mold (not shown) is provided having an inner mold surface whose dimensions and shape correspond to the dimensions and shape of the foam insert 80. Next, a polymeric material, such as a two-component (2K) polymeric material, is injected into the mold and foamed with a foaming agent to fill the cavity portion, thereby forming the foam insert 80. The mold is opened, and the foam insert 80 is removed from the mold. Depending on the composition of the polymeric material used, any additives included, and the foaming agent, the resulting foam insert 80 can be formed as a closed-cell foam or an open-cell foam and can have different physical and mechanical properties, including but not limited to: different densities, compressive strengths, specific gravities, stiffness, resilience, etc. The formed foam insert 80 includes one or more openings 82 through which fasteners 90 extend, or one or more openings 82 can be formed after the foaming step by drilling holes at desired locations in the elastomeric insert 80.

[0075] In one exemplary embodiment, the foam insert 80 is a polyurethane foam, and more preferably a flexible polyurethane foam formed using the NCFI 30-052 flexible foam system, which is described as a two-component, water-blown, polyether, all-polymer diphenylmethane diisocyanate (PMDI) based flexible foam system, commercially available from Barnhardt Manufacturing Co., Aire Hill, North Carolina.

[0076] Next, the elastomeric insert 80 is adhered to the structural member 100 and optionally to the additional support structure 120. This can be accomplished by applying an adhesive (e.g., glue) to a portion of the outer surface 110 of the structural member 100 and optionally to the additional support structure 120 to which the elastomeric insert 80 is to be attached. In an alternative embodiment, fasteners (not shown) (used alone or in combination with an adhesive) may also be used to adhere the elastomeric insert 80 to the structural member 100. In the adhered state, the opening 82 in the elastomeric insert 80 is aligned with the corresponding opening 111 in the structural member 100.

[0077] Next, the external elastomer member 60 is coupled to the structural member 100 such that the structural member 100 is partially housed within the cavity 66, and wherein the elastomer insert 80 is positioned within the cavity 66.

[0078] According to one embodiment of the present invention, a "slush molding" process (i.e., casting process) can be used to form the external elastomeric member 60 and the skin 62. In this process, a mold (not shown) is provided having an inner mold surface whose dimensions and shape are designed to accept the pre-assembled structural member 110 and the elastomeric insert 80, and includes additional space corresponding to the dimensions and shape of the external elastomeric member 60. The mold is filled with a polymeric material for forming the skin 62, typically a vinyl polymer or polyurethane. The vinyl or polyurethane is allowed to remain for a sufficient period of time to cure along the outer mold surface to form the skin 62 (i.e., forming a vinyl skin 62 or a polyurethane skin 62). Next, the polymeric material is injected into the mold and foamed to fill the cavity portion 64, thereby forming the external elastomeric member 60. The polymeric material (i.e., the first material) may have the same composition as the polymeric material used for the elastomeric insert 80 (i.e., the second material), but typically has a different composition than the polymeric material used to form the elastomeric insert 80, and is typically a two-component (2K) polymeric material introduced into the cavity portion 64. Unlike the method for forming insert 80, this process does not involve a foaming agent, and therefore the formed external elastomer component 60 is solid, not foam. The mold is opened, and the external elastomer component 60 with skin 62 is removed from the mold.

[0079] For example, in one exemplary embodiment, the M-3130 REV 1 A / B polyurethane elastomer system, which is commercially available from BJB Enterprises in Tustin, California, is used, and the outer elastomer member 60 is formed as a solid polyurethane elastomer (i.e., unfoamed) having a hardness range of 15 to 30 Shore A.

[0080] While the external elastomer component 60 formed using the M-3130 REV 1 A / B polyurethane elastomer system has a set of desired physical and mechanical properties, other external elastomer components 60 with different physical and mechanical properties (including different densities, compressive strengths, specific gravities, stiffnesses, resiliences, etc.) can also be used. Furthermore, certain additives can be introduced into the two-component (2K) polymer material before injection molding to adjust any physical or mechanical properties as needed.

[0081] During this step, the external elastomer member 60 and the skin 62 are formed to include a rearward opening 68, and one or more of the openings 72 therein are aligned with one or more openings 82 in the elastomer insert 80.

[0082] Similar to the method of forming insert 80, opening 72 in external elastomer member 60 and skin 62 can be formed during the casting process, or openings 72 and 80 in both external elastomer member 60 and insert 80 can be formed in an additional post-forming step by means of drilling or the like.

[0083] In addition, the rear opening 68 can also be formed in a post-casting step by removing, cutting or otherwise removing material from the external elastomeric member 60 and the skin 62.

[0084] Next, and if not pre-assembled in the previous steps, the mounting interface 114 is connected, fastened or otherwise secured to the inner surface 105 of the structural member 100.

[0085] Furthermore, the first set of electronic components (if employed) can be introduced through the rearward opening 68 of the external elastomeric member 60 and then secured, fastened, or otherwise coupled to the outer surface 110 of the structural member 100 corresponding to the rearward opening 68. As part of this step, the first set of electronic components can then be connected to any power cable, etc.

[0086] Next, the cover plate 150 is positioned within the rear opening 68 and is mounted to the outer surface 110 of the structural member 100 using one or more cover plate fasteners 152, such that the first set of components is positioned between the outer surface 110 of the structural member 100 and the cover plate 150.

[0087] Next, the spinal assembly 15 is lowered into the pelvic cavity 66, where the second set of electronic components is positioned near the mounting plate 118.

[0088] Then, the spine assembly 15 is installed onto the structural member 100 by sequentially introducing one or more fasteners 90 (shown as bolts 90) through the opening 72 in the outer elastomer member 60, the opening 82 in the elastomer insert, the opening 111 in the structural member 100 (which engages with the structural member 100), the opening 112 in the mounting interface 114 located on the inner surface 105 of the structural member 100 (which engages with the mounting interface 114), and then into and engaging the corresponding opening in the mounting plate.

[0089] Preferably, and as described above, the external elastomeric member 60 with skin 62 is combined with the elastomeric insert 80 and is in an assembled state as part of the anthropomorphic testing device 12 (as provided herein), which together provide a probe force measurement in the hip region 56 in the range of 1100 N to 2300 N when a conventional pendulum test is used, wherein the probe force is measured by impacting the hip region 56 with a 20 kg ballistic pendulum impactor at an impact velocity of 2.0 m / s.

[0090] This disclosure also describes a system 1000 that uses a software application included on a computer 1030 to create a virtual anthropomorphic test apparatus and evaluate the created virtual anthropomorphic test apparatus in a virtual crash test. The structural component 100', elastomer insert 80', and external elastomer component 60' of the anthropomorphic test apparatus are shown in Figures 25-29, and are virtual representations of a portion of the aforementioned anthropomorphic test apparatus. Figures 25-29 show representative virtual features of the anthropomorphic test apparatus, with reference numerals corresponding to… Figures 1-18 The illustration features are marked with apostrophes.

[0091] Now for reference Figure 24 The computer 1030 used to create the anthropomorphic test device 12' may include at least one processor 1032, memory 1034, mass storage device 1036, input / output (I / O) interface 1038, and human-machine interface (HMI) 1040. The computer 1030 may also be operatively connected to one or more external resources 1042 via a network 1013 and / or I / O interface 1038. External resources may include, but are not limited to, servers, databases, mass storage devices, peripherals, cloud-based network services, or any other suitable computing resources that the computer 1030 may use.

[0092] Processor 1032 may include one or more devices selected from: microprocessors, microcontrollers, digital signal processors, microcomputers, central processing units, field-programmable gate arrays, programmable logic devices, state machines, logic circuits, analog circuits, digital circuits, or any other device that manipulates signals (analog or digital) based on operating instructions stored in memory 1034. Memory 1034 may include a single storage device or multiple storage devices, including but not limited to: read-only memory (ROM), random access memory (RAM), volatile memory, non-volatile memory, static random access memory (SRAM), dynamic random access memory (DRAM), flash memory, cache memory, or any other device capable of storing information. Mass storage memory device 1036 may include data storage devices such as hard disk drives, optical disk drives, magnetic tape drives, non-volatile solid-state devices, or any other device capable of storing information. Database 1044 may reside on mass storage memory device 1036 and may be used to collect and organize data used by the various systems and modules described herein.

[0093] Processor 1032 may run under the control of operating system 1046 residing in memory 1034. Operating system 1046 may manage computing resources, enabling computer program code embodied as one or more computer software applications (such as application 1048 residing in memory 1034) to have instructions executable by processor 1032. In an alternative embodiment, processor 1032 may directly execute application 1048, in which case operating system 1046 may be omitted. One or more data structures 1050 may also reside in memory 1034 and may be used by processor 1032, operating system 1046, and / or application 1048 to store or manipulate data. Software application 1048, as provided herein, includes software applications for creating virtual anthropomorphic test equipment 10' and software applications for evaluating the created virtual anthropomorphic test equipment 10' in a virtual crash test setting.

[0094] I / O interface 1038 can provide a machine interface that operatively connects processor 1032 to other devices and systems, such as network 1013 and / or external resources 1042. Therefore, by communicating via I / O interface 1038, application 1048 can cooperate with network 1013 and / or external resources 1042 to provide various features, functions, applications, processes, and / or modules including embodiments of the present invention. Application 1048 may also have program code executed by one or more external resources 1042, or otherwise rely on functionality and / or signals provided by other systems or network components outside of computer 1030. In fact, given the virtually unlimited hardware and software configurations that can exist, those skilled in the art will understand that embodiments of the present invention can include applications located outside of computer 1030, distributed across multiple computers or other external resources 1042, or provided by computing resources (hardware and software) as a service (such as cloud computing services) provided via network 1013.

[0095] HMI 1040 can be operatively coupled to processor 1032 of computer 1030 in a known manner to allow a user of computer 1030 to interact directly with computer 1030. HMI 1040 may include a video and / or alphanumeric display, a touchscreen, speakers, and any other suitable audio and visual indicators capable of providing information to the user. HMI 1040 may also include input devices and controls capable of accepting commands or input from the user and transmitting the input to processor 1032, such as an alphanumeric keypad, a pointing device, a keypad, buttons, control knobs, a microphone, etc.

[0096] This disclosure is described in an illustrative manner. It should be understood that the terminology used is intended to be descriptive rather than restrictive.

[0097] In view of the above teachings, many modifications and variations of this disclosure are possible. Therefore, this disclosure may be implemented in ways different from those specifically described.

Claims

1. A pelvic component of an anthropomorphic testing device, characterized in that, The pelvic assembly includes: Pelvic components, including: An external elastomer member formed of a first material, wherein the external elastomer member defines a pelvic cavity and an inner cavity, and An elastomeric insert formed of a second material and partially positioned within the inner cavity; and A structural member, formed of a rigid material and partially housed within the cavity and exposed to the pelvic cavity, wherein an elastomeric insert is coupled to the structural member and positioned between the external elastomeric member and the structural member. The second material of the elastomeric insert is different in composition or mechanical properties from the first material of the external elastomeric member, and The external elastomer member and the elastomer insert are sized and shaped to approximate the compression characteristics of a human sitting on the structure during crash test simulations.

2. The pelvic assembly as described in claim 1, characterized in that, The elastomeric insert includes a foam insert.

3. The pelvic assembly as described in claim 1 or claim 2, characterized in that, The external elastomer component comprises a solid polyurethane material covered with a skin.

4. The pelvic assembly as claimed in claim 1 or claim 2, characterized in that, The elastomeric insert comprises flexible polyurethane foam.

5. The pelvic assembly as claimed in claim 1 or claim 2, characterized in that, The elastomeric insert is adhered to the outer surface of the structural member using an adhesive.

6. The pelvic assembly as claimed in claim 1 or claim 2, characterized in that, Each of the external elastomer member and the elastomer insert defines one or more openings, the one or more openings being configured to receive one or more fasteners extending through the one or more openings in the external elastomer member and the elastomer insert to engage the structural member.

7. The pelvic assembly as claimed in claim 1 or claim 2, characterized in that, The external elastomer component includes: Abdominal region A pair of thigh areas, and Connect the abdominal region to the hip region of each of the pair of thigh regions.

8. The pelvic assembly as claimed in claim 7, characterized in that, Each of the hip region of the external elastomer member and the elastomer insert defines one or more openings, the one or more openings being configured to receive one or more fasteners extending through the one or more openings in the external elastomer member and the elastomer insert to engage the structural member.

9. The pelvic assembly as claimed in claim 7, characterized in that, The hip region of the external elastomer member defines one or more rearward openings that allow access to the structural member partially housed within the cavity.

10. The pelvic assembly as claimed in claim 8, characterized in that, The hip region of the external elastomer member defines one or more rearward openings that allow access to the structural member partially housed within the cavity.

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