Crash test sled for vehicle cargo area

Abstract

A crash test sled replicating the rear cargo area of a vehicle for testing safety of animals in the rear cargo area, occupants in a vehicle seat in front of the rear cargo area, or both, is disclosed. The crash test sled includes a cargo area structure having a floor, a wall, a seatback panel positioned forward of the floor, and a roof panel. The crash test sled further includes a sensor assembly configured to determine crash forces at areas of interest, including an impact force applied to the seatback panel during an impact event (e.g., crash). Optionally, the crash test sled further includes a horizontal member or a linkage assembly supporting the seatback panel.

Description

AP-24138-3520-WG000CRASH TEST SLED FOR VEHICLE CARGO AREACROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims priority to U.S. Provisional Application Serial No. 63 / 691,696, filed September 6, 2024.BACKGROUND

[0002] Crash testing for vehicles is typically focused on the safety of human occupants in vehicle seats, and as such most crash tests do not study or fully replicate a rear cargo area. When an animal, such as a pet dog, occupies the rear cargo area, there are crash injury risks to both the animal and any human occupants. Moreover, if a dog is in a crate in the rear cargo area, then the crate will influence crash injury risks. Some dog crates include various safety features and attachment features for use in a rear cargo area.SUMMARY

[0003] The present disclosure also relates to a crash test sled and a method of using the same for crash testing objects in a rear cargo area of a vehicle, such as an animal containment unit or crate.

[0004] In some embodiments, the present disclosure relates to a crash test sled for a rear cargo area of a vehicle. The crash test sled may include a cargo area structure having a floor, a wall, a seatback panel positioned forward of the floor, a front support frame supporting the seatback panel, and a roof panel. The front support frame may include a horizontal member connected to the seatback panel and extending forward of the seatback panel. The crash test sled may further include a sensor assembly configured to determine an impact force applied to the seatback panel during an impact event (e.g., crash).

[0005] In some embodiments, the present disclosure relates to a crash test sled for a rear cargo area of a vehicle. The crash test sled may include a cargo area structure having a floor and a seatback panel positioned forward of the floor. The crash test sled may further include a linkage assembly supporting the seatback panel. The crash test sled may further include a sensor assembly configured to determine an impact force applied to the seatback panel during an impact event.

[0006] In some embodiments, the present disclosure relates to a crash test sled for a rear cargo area of a vehicle. The crash test sled may include a cargo area structure that includes a seatback panel. The crash test sled may further include a linkage assembly that includes a shock absorber assembly and one or more pivotable links connecting the seatback panel to the shock absorber assembly.

[0007] In some embodiments, the present disclosure also relates to a method of using a crash test sled for a rear cargo area of a vehicle. The method may include mounting a load sensor of a sensor assembly to a surface of a cargo area structure. The sensor assembly may be configured to determine an impact force applied to a seatback panel of the cargo area structure during an impact event. The method may further include disposing a containment device on a base of the cargo area structure. The containment device may be disposed a predetermined distance rearward of the seatback panel, the predetermined distance being between about 175 millimeters (mm) and about 225 mm. The method may further include placing a weight device in the containment device. The weight device may have a predetermined mass, the predetermined mass being between about 15 kilograms (kg) and about 20 kg. The method may further include determining, by the sensor assembly, the impact force applied to the seatback panel during the impact event.

[0008] In some embodiments, the present disclosure relates to a method of manufacturing a crash test sled for a rear cargo area of a vehicle. The method may include forming a cargo area structure having a floor, a seatback panel positioned forward of the floor, and a roof panel. The method may further include mounting a sensor assembly to the cargo area structure. The sensor assembly may be configured to determine an impact force applied to the seatback panel during an impact event.AP-24138-3520-WG000BRIEF DESCRIPTION OF THE DRAWINGS

[0009] FIGS. 1A and IB show partially cutaway top and side views of an arrangement for a standard ECE R17 crash test;

[0010] FIG. 1C shows a graph of example frontal impact crash results for the standard ECE R17 crash test;

[0011] FIG. 2 is a partial cross-sectional side view of a crash test arrangement according to embodiments of the present disclosure;

[0012] FIG. 3 is a perspective view of a crash test sled according to embodiments;

[0013] FIG. 4 is a side view of the crash test sled of FIG. 3 including a test weight;

[0014] FIG. 5 is a perspective view of a crash test sled according to embodiments;

[0015] FIG. 6 is a detailed partial perspective view of the crash test sled of FIG. 5;

[0016] FIG. 7 is a side view of the crash test sled of FIG. 5;

[0017] FIG. 8 is a partial cross-sectional side perspective view of the crash test sled of FIG. 5;

[0018] FIG. 9 is a detailed partial rear perspective view of the crash test sled of FIG. 5;

[0019] FIG. 10 is a perspective view of a portion of a rear cargo assembly for a cargo sled according to embodiments;

[0020] FIG. 11 is a partial perspective view of a portion of a rear cargo assembly for a cargo sled according to embodiments;

[0021] FIG. 12 is a perspective view of a tie down component according to embodiments;

[0022] FIG. 13 is a side view of a crash test sled according to embodiments including a superimposed scan of an existing vehicle rear cargo area;

[0023] FIG. 14 is a perspective view of a crash test sled according to embodiments;

[0024] FIG. 15 is a perspective view of a linkage assembly according to embodiments;

[0025] FIG. 16 is a perspective view of a linkage assembly according to embodiments;AP-24138-3520-WG000

[0026] FIG. 17 is a side view of a linkage system according to embodiments;

[0027] FIG. 18 is a side view of a shock absorber assembly according to embodiments;

[0028] FIG. 19 is a graph of force versus displacement for a linkage assembly under test according to embodiments;

[0029] FIG. 20 is a side view of a portion of a crash test sled in a rest position according to embodiments;

[0030] FIG. 21 is a side view of a portion of the crash test sled shown in FIG. 21 in a compressed position following an impact event according to embodiments;

[0031] FIG. 22 is a side view of a crash test sled according to embodiments;

[0032] FIG. 23 is a side view of a crash test sled according to embodiments;

[0033] FIG. 24 is a flow chart of an example method of using a crash test sled for a rear cargo area of a vehicle according to embodiments;

[0034] FIG. 25 is a flow chart of an example method of manufacturing a crash test sled for a rear cargo area of a vehicle according to embodiments;

[0035] FIG. 26 is a perspective view of a crash test sled according to embodiments;

[0036] FIG. 27 is an exploded view of a linkage assembly included in the crash test sled shown FIG. 26 according to embodiments;

[0037] FIG. 28 is a perspective view of a hnkage system included in the linkage assembly shown in FIG. 27 according to embodiments;

[0038] FIG. 29 is a side view of the linkage system of FIG. 28 according to embodiments;

[0039] FIG. 30 is a front perspective view of a crash test sled according to embodiments;

[0040] FIG. 31 is a side view of a crash test sled according to embodiments;

[0041] FIG. 32 is a front view of a crash test sled according to embodiments;

[0042] FIG. 33 is a side view of a crash test sled according to embodiments;

[0043] FIG. 34 is an enlarged portion of FIG. 33;

[0044] FIG. 35 is a rear perspective view of a crash test sled according to embodiments;AP-24138-3520-WG000

[0045] FIG. 36 is an enlarged portion of FIG. 35;

[0046] FIG. 37 is a bottom perspective view of a crash test sled according to embodiments;

[0047] FIG. 38 is a rear perspective view of a crash test sled according to embodiments;

[0048] FIG. 39 is a perspective view of an interface of a roof assembly and an upper structure assembly of a crash test sled according to embodiments; andDETAILED DESCRIPTION

[0049] The example embodiments may be further understood with reference to the following description and the related appended drawings, wherein like elements are provided with the same reference numerals.

[0050] The crash test sled of the present disclosure replicates a rear cargo area of a vehicle, in whole or in part. In embodiments, the crash test sled may be used to crash test an animal containment unit installed therein, which may further include an animal test dummy (ATD). The animal containment unit may be referred to alternatively as an animal crate, a dog crate, crate, cage, etc. and may be used for transporting various types of animal(s) or other cargo without departing from the scope of the disclosure. Those skilled in the art will understand that the animal containment unit is configured to safely hold an animal during, e.g., transportation of the animal in a moving vehicle and / or for transportation of the animal outside the vehicle. Some animal crates may include a base, docking station, or the like that may also be evaluated in crash tests.

[0051] With reference to FIGS. 1A-C, illustrated is the basic arrangement of international regulation on rear seat strength testing and resulting data pursuant to, for example, Regulation No. 17 of the Economic Commission for Europe of the United Nations (UN / ECE), titled “Uniform provisions concerning the approval of vehicles with regard to the seats, their anchorages and any head restraints,” (referred to herein as “ECE R17”). Aspects of the ECE R17 may be implemented with crash test sleds as shown herein, such as acceleration / deceleration and installation of weights.AP-24138-3520-WG000It will be appreciated that the ECE R17 has various shortcomings, for example it is not intended for evaluating the safety of an animal in the rear cargo area of a vehicle or the crash performance of an animal crate. Embodiments of the present disclosure are intended to develop and create a test procedure that considers a full cargo area and has one or more of: a defined cargo space with roof structure (e.g., including one or more roof panels), cargo anchors (e.g., tiedown anchors), and a rear seat panel with sensors, such as load cell sensors, to measure, calculate, or otherwise determine force applied by an animal crate during an impact event (e.g., a crash, or a simulated crash or crash test). In some embodiments, the test procedure follows or modifies certain aspects of ECE R17 procedures.

[0052] Referring to FIG. 2, an example of a crash test sled 20A is shown according to embodiments. The crash test sled 20A has various aspects and components that replicate part of a vehicle, including a seatback panel 22 and a rear cargo area 2 structure 4 behind the seatback panel 22. The seatback panel 22 may be an actual vehicle seat or component thereof, or it may be a panel sized and arranged to replicate a seatback. The rear cargo area structure 24 comprises a floor 26, a rear door 28 (e.g., vehicle hatch door), and a roof panel 30. Sidewalls (not shown) may likewise be included to form a substantially enclosed rear cargo area structure 24. One or more tiedown anchors 40 may be provided in the rear cargo area structure 24, such as on the floor 26 and / or other locations. The crash test sled 20A may likewise include a front support frame 50 supporting the seatback panel 22. In embodiments various sensors, for example load cell sensors, (not shown) may be mounted to the front support frame 50 or the seatback panel 22 to evaluate crash test information. A containment device 90 (e.g., an animal crate) may be installed in the rear cargo area structure 24 for evaluation.

[0053] Referring to FIGS. 3 and 4, another example of a crash test sled 20B is shown according to embodiments. The crash test sled 20B includes a seatback panel 22 supported by a front support frame 50 and a rear cargo area structure 24 having a floor 26. The rear cargo area structure 24 may also include one or more nonillustrated features including a rear door, roof panel, and / or sidewalls. A docking base94 and / or a containment device 90 may be installed and receive a weight device 92 (e.g., a test weight) thereon. The weight device may have a predetermined mass and configured to be positioned a predetermined distance rearward of the seatback panel 22. For example, the predetermined mass may be between about 15 kilograms (kg) and about 20 kg, and the predetermined distance may be between about 175 millimeters (mm) and about 225 mm. In some embodiments, the containment device 90 may be positioned rearward of the seatback panel 22, and the weight device 92 may be disposed within the containment device 90. The containment device 90 and the weight device 92 may include various sensors, including load cell sensors or cameras within the containment device, for additional measurement and determination of crash performance relative to an animal occupant within the containment device.

[0054] In some embodiments, the docking base 94 or the containment device 90 may include a load leg 96 (e.g., a horizontal load leg) extending forward therefrom for engaging the seatback panel 22 and providing a controlled transfer of forces during a crash. In embodiments, the weight device 92 may weigh about 18.0 kg. Various other weights are contemplated, in particular weights corresponding to different size categories of animals (e.g., 15 pounds (lbs.), 30 lbs., 50 lbs., 75 lbs., 100 lbs., etc.). In embodiments, the front of the weight is located a predetermined distance DI from the seatback panel 22. In the ECE R17 test, DI is 200 mm. In embodiments, the front of the containment device 90 is located a predetermined distance from the seatback panel 22. In some embodiments, the floor 26 may be designed to provide a predetermined coefficient of friction for certain materials, for example a coefficient of friction of 0.5 for acrylonitrile butadiene styrene (ABS) on carpet.

[0055] As shown in FIG. 3, the seatback panel 22 may be formed of multiple parts, in the illustrated example a seatback panel 22A is supported by a seatback frame 22B and a seatback crossbar 22C. It will be appreciated that the seatback panel 22 is formed of materials with suitable properties (e.g., weight, strength, rigidity) to repbcate a vehicle seat.AP-24138-3520-WG000

[0056] As shown in FIG. 4, the front support frame 50 may comprise various components. In some embodiments, the front support frame 50 includes one or more horizontal members 52 extending forward of the seatback panel 22 and a bottom mount 54. In embodiments, the bottom mount 54 is pivotable at a pivot point 56, providing a similar arrangement to a vehicle seat. In embodiments, the pivot point 56 is located below the floor 26 of the rear cargo area by a distance of D2. Additional frame structures may support and position the front support frame 50, such as vertical frame members 58, and angled frame members 60. In embodiments, most of the front support frame provides fixed joints 62 (e.g., non-pivoting connections). One or more crossbars 64 (FIG. 3) may be included. The crash test sled 20B may include a front floor 65 for supporting the front support frame 50.

[0057] During embodiments of a crash test, the crash test sled 20B moves forward (e.g., leftward as shown in FIG. 4) and then a force Fl may be applied (e.g., a force similar to the test pulse in the ECE R17 test), which results in the weight device 92 moving due to inertia and applying a force F2 toward the seatback panel 22. Various sensors (not shown) may be mounted to the front support frame 50 or the seatback panel 22 to evaluate crash test information. In some embodiments, a sensor assembly having multiple sensors may be mounted to the horizontal member 52. For example, the sensor assembly may include a load sensor (e.g., alload cell sensor) mounted to a surface of the horizontal member 52. In embodiments sensors may be mounted to the bottom mount 54, for example to measure, calculate, or otherwise determine rotational forces on the pivot point 56.

[0058] Referring to FIGS. 5-12, another example of a crash test sled 120 is shown according to embodiments. The crash test sled 120 includes a seatback panel 122 supported by a front support frame 150 and a rear cargo area structure 124 having a floor 126, a rear panel 128, a roof panel 130, and sidewalls 132. The crash test sled may also include a rear frame 170. The front support frame 150 and / or the rear frame 170 may support the roof panel 130. As shown in FIG. 7, the cargo area structure 124 includes a front floor anchor 123, and the seatback panel 122 is pivotably mounted to the front floor anchor 123. In some aspects, the front floor anchor 123 may include,AP-24138-3520-WG000 but is not limited to, one or more bottom mounts (e.g., bottom mount 154 shown in FIG. 6) and pivot points (e.g., pivot point 156 shown in FIG. 6).

[0059] As shown in FIGS. 7 and 9, the horizontal member 152 of the front support frame 150 may be provided as a pair of horizontal members 152 laterally spaced. The horizontal member 152 may include a rear pivot mount 163A at a joint with the seatback panel 122 and / or may include a front pivot mount 163B at a joint with the rest of the front support frame 150. One or more of the horizontal members 152 may be instrumented to include sensors to measure, calculate, or otherwise determine impact forces. In some embodiments, one of the rear pivot mount 163A and the front pivot mount 163B includes a shear pin that is designed to fail under a predetermined force that corresponds to an acceptable amount of force delivered to the seatback panel 122; in this manner, a broken shear pin provides a clear pass-fail result for a crash test.

[0060] One or more of the rear pivot mount 163A and the front pivot mount 163B may comprise a pivot pin, and in certain embodiments the pivot pin may comprise a material that is relatively weaker and / or more resilient (e.g., a weaker alloy metal than the rest of the seatback frame 122C and / or the front support frame 150), allowing the pivot pin to bend during a crash to help absorb some forces. The pivot point 156 of the bottom mount 154 of the front support frame 150 may comprise a pivot pin that is similarly arranged. In this manner, embodiments with one or more of the pivot point 156, rear pivot mount 163A, and front pivot mount 163B, allow the seatback panel 122 to move relative to the crash test sled 120 during a crash. Additionally or alternatively, the seatback panel 122 may be selectively adjustable due to one or more of the pivot point 156, rear pivot mount 163A, and front pivot mount 163B.

[0061] For the crash test sled 120, front support frame 150, and rear frame 170, or portions thereof, the following construction and materials may be implemented in some embodiments as metal frame components rigidly connected together. In embodiments, the metal frame components are hollow tubing that is welded or boltedAP-24138-3520-WG000 together. In some embodiments, the metal frame components are 2 inch (in.) square structural steel tubing.

[0062] In embodiments, the roof panel 130 may be constructed as one or more of: 1 / 8 in. steel panels (e.g., roof panels 130A, 130B, and 130C) supported by a backing frame, covered by a 1 / 8 in. plastic cover for realism to the inside of a car. The backing frame may be rigidly constructed 1 in. or 2 in. square structural steel tubing. The roof panel 130 is designed to outline the allotted space in a vehicle for more realistic testing. In embodiments, the roof panel 130 comprises one or more of a front roof panel 130A, a middle roof panel 130B, and a rear roof panel 130C. In embodiments, the rear roof panel 130C has a lower height than the front roof panel 130A. In embodiments, the middle roof panel 130B is angled to span between the front roof panel 130A and the rear roof panel 130C.

[0063] The rear cargo area structure 124 of the present disclosure provides a substantial majority of the physical parts that may interact with a containment device 90 during a crash. Moreover, the containment device 90 may include features to interact with one or more parts of the rear cargo area structure 124, in the same manner as the load leg 96 engaging the seatback panel 22 (FIG. 4). In some embodiments, the roof panel 130 may be engaged by the containment device 90 and / or base 94 in various ways, for example vertical load legs (not shown, similar to the load leg 96 of FIG. 4) or tethers. The floor 126, sidewalls 132, and rear panel 128 may also be engaged by the containment device 90 in various ways.

[0064] In embodiments, the following material construction may be implemented for one or more of the floor 126, rear panel 128, roof panel 130 (including, but not limited to, roof panels 130A, 130B, and 130C), sidewalls 132: 1 / 8 in. steel panels being a support panel, and a cover of 1 / 8 in. carpet or plastic for realism and to absorb impact forces. Various other thicknesses and materials are contemplated. Moreover, one or more of the floor 126, rear panel 128, roof panels 130A-C, sidewalls 132 may have a backing frame formed of 1 in. or 2 in. square structural steel tubing.

[0065] In some embodiments, the cargo area structure of the crash test sled 120 may include a tiedown anchor, also referred to as a “cable tiedown anchor,” “cableAP-24138-3520-WG000 tiedown,” and / or “tiedown,” rated up to 500 lbs. For example, one or more tiedown anchors 140 may be configured with weight rating, size, placement, etc. that are more closely related to tie downs seen in vehicles, and in embodiments may rotate. In embodiments, the one or more tiedown anchors 140 may be respectively located adjacent to one or more corners of the floor 126 and / or the roof panel 130. In examples, each of the one or more tiedown anchors 140 may be rated for about 100 lbs., 200 lbs., 300 lbs., 400 lbs., 500 lbs., 600 lbs., 700 lbs., 800 lbs., 900 lbs., 1000 lbs. or more, or ranges therebetween. The one or more tiedown anchors 140 may be designed to have a predetermined strength selected to replicate a particular vehicle tiedown strength, the average strength available in a certain vehicle class, the maximum available in a certain vehicle class, or the like. Generally, the one or more tiedown anchors 140 may be rated for up to 2,000 lbs., up to 1,500 lbs., up to 1,000 lbs., up to 750 lbs., up to 500 lbs., up to 250 lbs., or up to 125 lbs. In some embodiments, tiedown anchors may be provided at other locations, or load straps may extend from the containment device 90 to other locations on the crash test sled 120 (e.g., at the top or bottom of the rear door 28 shown in FIG. 2 to replicate a load strap that passes through a door jamb.

[0066] Referring to FIGS. 5 and 7, in embodiments the crash test sled 120 may include one or more camera mounts 180A, 180B, and 180C, which may be similar to camera mounts utihzed in infant / child car seat crash testing. The crash test sled 120 may include an excursion marker 182 for determining (e.g., measuring, calculating, and the like) and / or tracking movement of the seatback panel 122 and / or other components during a crash. One skilled in the art will appreciate that measurement or observation of the amount of movement of the seatback panel 122 may be used to infer, calculate, or otherwise determine the amount of force applied to the seatback panel. Accordingly, a camera may constitute or supplement the sensor assembly.

[0067] As shown in FIG. 13, in some embodiments, the cargo space is comparable to measurements from a 3-D scan of a predetermined vehicle. The crash test sled 220 and cargo area structure 224 in the illustrated embodiment are sized to correspond to a scan 200 of a 2010 Chevrolet® Tahoe. Various other vehicles or vehicle classesAP-24138-3520-WG000(e.g., sport utility vehicle (SUV), crossover, wagon, minivan, etc.) may be implemented for the dimensions of the cargo area structure 224.

[0068] FIG. 14 is a perspective view of a crash test sled 300 for a rear cargo area of a vehicle according to embodiments. As shown, the crash test sled 300 includes a seatback panel 322 and may include a cargo area structure 324 including one or more of a floor 326, a rear panel 328, and sidewalls 332. The crash test sled 300 may further include a sensor assembly (e.g., comprising one or more load cell sensors, cameras, or the like) configured to measure, calculate, or otherwise determine an impact force applied to the seatback panel 322 during an impact event. As shown, the crash test sled 300 may further include a linkage assembly 352 supporting the seatback panel 322 and connected to a front support frame 350. In some aspects, the linkage assembly 352 may be utilized to adjust, modify, or otherwise control forces or movement in the crash test sled 300, such as to simulate, replicate, or mimic the actions of a second-row seatback in the event of a crash. In some aspects, the linkage assembly 352 may provide a leverage profile which compresses a spring a large amount in the beginning of the travel, and much less at the end, which gives the force profile described below with reference to, for example, FIGS. 17 and 19.

[0069] FIG. 15 is a perspective view of the linkage assembly 352 according to embodiments. As shown, the linkage assembly 352 may include a left linkage system 354A and a right linkage system 354B.

[0070] FIG. 16 is another perspective view of the linkage assembly 352 according to embodiments. As shown, the left linkage system 354A may include a clevis structure 378A and the right linkage system 354B may include a clevis structure 378B.

[0071] FIG. 17 is a side view of a linkage system 354 (e.g., left linkage system 354A, right linkage system 354B) of the linkage assembly 352 according to embodiments. As shown, the linkage system 354 may include a connecting link 360 pivotably mounted to the seatback panel 322, a rocker link 362, a primary shock link 364, a secondary shock link 366, a clevis structure 368, and a shock absorber assembly 370 (e.g., compression spring and damper). As shown, the shock absorber assembly 370AP-24138-3520-WG000 includes a first portion (e.g., a proximal end) pivotably mounted to the clevis structure 368. As shown, the cargo area structure 324 and / or the front support frame 350 may include a front floor anchor 372, and the shock absorber assembly 370 has a second portion (e.g., a distal end) that is pivotably mounted to the front floor anchor 372.

[0072] In some embodiments, as shown, the linkage system 354 utilizes four different links to manipulate the rate at which the spring in the shock absorber assembly 370 is compressed. In some aspects, a large impact force may be applied to the seatback panel 322 to move the seatback initially and the impact force may subsequently taper to a lesser impact force later in the seatback panel 322’s movement. Generally speaking, the linkage system 354 includes one or more pivotable Enks connecting the seatback panel 322 to the shock absorber assembly 370 in a manner that replicates the mounting of a seat in a vehicle, or the mounting of a seatback panel in the ECE R17 test (such as a shear pin designed to fail under a predetermined force, as discussed above with reference to the rear pivot mount 163A and the front pivot mount 163B). In various embodiments, the linkage system 354 includes one link, two hnks, tEree Enks, four Enks (as iUustrated), five Enks, six Enks, or more. In various embodiments, the linkage system 354 includes a shear pin (not shown) configured to fail in response to an application of a predetermined impact force to the seatback panel 322, such as when the impact force applied to the seatback panel 322 during an impact event (e.g., crash) is greater than the predetermined impact force.

[0073] In some embodiments, as shown, a connecting hnk 360 attaches the seatback panel 322 to the rest of the linkage system 354, starting with the rocker link 362. In the illustrated embodiment, the links of the linkage system 354 are mounted with pivotable connections at each connection point. The rocker link 362 is pivotably connected to a first fixed portion 363 of the crash test sled 300. In some aspects, the rocker Enk 362 is configured to contribute to decreasing the amount of movement required of the springs of the shock absorber assembly 370 such that sourcing may be possible. The rocker Enk 362 tEen pusfies on tfie primary sfiock link 364. The primary shock link 364 connects the linkage system 354 to the shock absorberassembly 370 by use of a clevis structure 368. The clevis structure 368 may be utilized to increase the overall length of the shock absorber assembly 370, to increase space for the dampers that will occupy space where the spring is located, and, in some aspects, to allow the use of, for example, two shock absorber assemblies per clevis structure 368. As a result, in some aspects, a total of two clevis structures, four shock absorber assemblies, and four front floor anchors may be included in the crash test sled 300. In some embodiments, the clevis structure 368 does not substantially change the geometry of the links in the linkage system 354, but rather provides a way for a spring to be longer than the space allotted but still attach to the same location as to not disturb the geometry of the system by conforming to the shock absorber assemblies or springs that are available. In some aspects, the movement of the primary shock link 364 is controlled by the secondary shock link 366 (also referred to as the “upper shock link”), which is connected to a second fixed portion 367 of the crash test sled 300. The secondary shock link 366 is configured to push the primary shock link 364 downwards and attain the predetermined force curve. It will be appreciated that one or more of the illustrated clevis structures may be substituted with other pivoting structures known in the art.

[0074] The linkage system 354 provides the various links and the shock absorber assembly 370 to be pivotably attached to the crash test sled 300, each other, and the seatback panel 322. In the illustrated embodiment, a proximal end of the shock absorber assembly 370 is pivotably mounted to the crash test sled 300 at the front floor anchor 372 and a distal end is attached to the clevis structure 368. The clevis structure 368 is attached to a first end of the primary shock link 364, and a second end of the primary shock link is pivotably attached to the rocker link 362. The secondary shock link 366 has a first end pivotably attached to the primary shock link 364 between the first and second ends of the primary shock link 364, and in the illustrated embodiment is positioned closer to the first end of the primary shock link 364 (e.g., closer to the shock absorber assembly 370 than to the rocker link 362). The secondary shock link 366 has a second end attached to the second fixed portion 367 of the crash test sled 300. The rocker link 362 has a first end pivotably attached toAP-24138-3520-WG000 the primary shock link 364 and a second end pivotably attached to the first fixed portion 363 of the crash test sled 300. The connecting link 360 has a first end pivotably attached to the rocker link 362 and a second end pivotably attached to the seatback panel 322. The connecting link 360 is attached to the rocker link 362 between the ends of the rocker link 362, and in the illustrated embodiment is positioned closer to the first end of the rocker link 362 (e.g., closer to the primary shock link 364 than to the first fixed portion 363).

[0075] FIG. 18 is a side view of an example shock absorber assembly 470 according to embodiments. As shown, the shock absorber assembly 470 includes a spring 474 and a damper 476. As shown, the shock absorber assembly 470 includes: a proximal end 471 configured to be pivotably mounted to a clevis structure (e.g., clevis structure 368, 368 A, 368B); and a distal end 473 configured to be pivotably mounted to a front floor anchor (e.g., front floor anchor 372).

[0076] FIG. 19 is a graph 1900 of force versus displacement for a linkage assembly (e.g., linkage assembly 352) under test according to embodiments. As shown, curve 1902 represents the impact force in Newtons (N) applied to the seatback panel (e.g., seatback panel 322) throughout the travel during the test, and curve 1904 represents the wheel rate (amount of force needed to move one unit) in Newtons per millimeter (N / mm) throughout the travel. As shown, the linkage assembly provides a very precise way to simulate the force of breaking through a seat lock and into the occupant area.

[0077] FIG. 20 is a side view of a portion of a crash test sled 300 in a rest position according to embodiments. As shown in FIG. 20, the crash test sled 300 further includes a bump stop 301. FIG. 21 is a side view of a portion of the crash test sled 300 shown in FIG. 20 in a compressed position (e.g., 60 degrees from rest) following an impact event according to embodiments. As shown in FIG. 21, the linkage assembly 352 further includes a bump stop 353. As shown in FIGS. 20 and 21, the cargo area structure 324 further includes a front floor anchor 323 (including, but not limited to, one or more bottom mounts and pivot points), and the seatback panel 322 is pivotably mounted to the front floor anchor 323.AP-24138-3520-WG000

[0078] FIG. 22 is a side view of a crash test sled 500 that includes a roof assembly 333 mounted to the crash test sled 300 according to embodiments. In some embodiments, the roof assembly 333 is removable from the crash test sled 300 to make install easier and faster. As shown, the roof assembly 333 includes a roof support frame 331 and a roof panel 330. The roof support frame 331 may include steel tubing, such as 2 in. by 6 in. rectangular steel pipes, mounted to the crash test sled 300 as shown. In some aspects, the roof panel 330 may include multiple roof panels of different heights above the floor of the crash test sled 300 (e.g., similar to the structures and features discussed with reference to roof panel 130, 130A-C). In some aspects, the height of the roof panel 330 may be sized to correspond to an existing vehicle (e.g., a specific model of SUV).

[0079] FIG. 23 is a perspective view of a crash test sled 600 that includes the roof assembly 333 mounted to the crash test sled 300 according to embodiments. As shown, the crash test sled 600 further includes upper strap mounts 390 (e.g., two upper strap mounts), camera mounts 392, and camera mounts 393. In some aspects, the upper strap mounts 390 may be mounted to the roof assembly 333. For example, as shown, the upper strap mounts 390 are affixed to a rear portion of the roof panel 330. In some aspects, the camera mounts 392 may be mounted to the roof assembly 333. For example, as shown, the camera mounts 392 are affixed to portions of the roof support frame 331. In some aspects, the roof support frame 331 provides a rigid structure for placement of cameras to observe the crash event and, in some aspects, to observe the results of a loose containment device (e.g., animal crate) striking the roof panel. In some aspects, the camera mounts 393 may be implemented as side impact camera booms, as shown, which are removable from the crash test sled 300 to make install easier and faster. During a crash test, cameras may be used to measure, calculate, or otherwise determine the distance traveled forward by the seatback panel 322 (e.g., example relative to the excursion marker 182 shown in FIG. 7) or to measure, calculate, or otherwise determine the change in angle that the seatback pivots (e.g., comparing the orientation of the seatback in FIG. 20 to FIG. 21).AP-24138-3520-WG000

[0080] FIG. 24 is a flow chart of an example method 2400 of using a crash test sled for a rear cargo area of a vehicle according to aspects of the disclosure. It is noted that one or more steps may be combined, that certain steps may be omitted, and that the steps may be performed in any preferred order as desired.

[0081] At step 2402, the method 2400 includes mounting a load sensor of a sensor assembly to a surface of a cargo area structure, such as to a surface of a horizontal member (e.g., as described with reference to FIGS. 3-13) connected to a seatback panel of the cargo area structure, or to a surface of a linkage assembly (e.g., as described with reference to FIGS. 14-23) connected to a seatback panel of the cargo area structure. In some aspects, the sensor assembly may be configured to determine (e.g., measure, calculate, or the like) an impact force applied to the seatback panel during an impact event.

[0082] At step 2404, the method 2400 includes disposing a containment device on a floor of the cargo area structure (e.g., as described with reference to FIG. 4). In some aspects, the containment device may be disposed a predetermined distance rearward of the seatback panel. For example, the predetermined distance may be between about 175 millimeters (mm) and about 225 mm.

[0083] At step 2406, the method 2400 includes placing a weight device in the containment device (e.g., as described with reference to FIG. 4). In some aspects, the weight device may have a predetermined mass. F or example, the predetermined mass may be between about 15 kilograms (kg) and about 20 kg.

[0084] At step 2408, the method 2400 includes determining (e.g., measuring, calculating, or the like), by the sensor assembly, the impact force applied to the seatback panel during the impact event.

[0085] FIG. 25 is a flow chart of an example method 2500 of manufacturing a crash test sled for a rear cargo area of a vehicle according to aspects of the disclosure. It is noted that one or more steps may be combined, that certain steps may be omitted, and that the steps may be performed in any preferred order as desired.

[0086] At step 2502, the method 2500 includes forming a cargo area structure having a base, a wall, a seatback panel positioned forward of the base, and a roofpanel (e.g., as described with reference to FIGS. 2-4, FIGS. 5-13, and / or FIGS. 14- 23). Optionally, in some embodiments, the forming of the cargo area structure at step 2502 may include forming the roof panel to have a front portion and a rear portion. In some aspects, the rear portion may have a lower height than the front portion. Optionally, in some embodiments, the forming of the cargo area structure at step 2502 may include forming the cargo area structure to further include a front floor. Optionally, in some embodiments, the forming of the cargo area structure at step 2502 may include pivotably mounting the seatback panel to the front floor.

[0087] At step 2504, the method 2500 includes mounting a sensor assembly to the cargo area structure. The sensor assembly may be configured to determine (e.g., measure, calculate, or the like) an impact force applied to the seatback panel during an impact event.

[0088] Optionally, in some embodiments (e.g., as described with reference to FIGS. 5-13), the forming of the cargo area structure at step 2502 may include forming the cargo area structure to further include a front support frame comprising a horizontal member extending forward of the seatback panel. In some aspects, the horizontal member may include a first pivot mount at a first end of the horizontal member, and a second pivot mount at a second end of the horizontal member opposite the first end. Optionally, in some embodiments, the forming of the cargo area structure at step 2502 may further include mounting the first pivot mount of the horizontal member to the seatback panel by a first pivot pin. Optionally, in some embodiments, the forming of the cargo area structure at step 2502 may further include mounting the second pivot mount of the horizontal member to another portion of the front support frame by a second pivot pin. Optionally, in some embodiments, the mounting of the sensor assembly to the cargo area structure at step 2504 may include mounting a load sensor of the sensor assembly to a surface of the horizontal member.

[0089] Optionally, in some embodiments (e.g., as described with reference to FIGS. 14-23), the forming of the cargo area structure at step 2502 may include forming the cargo area structure to further include a linkage assembly supporting the seatback panel. In some aspects, the linkage assembly may include two linkage systems, whereAP-24138-3520-WG000 each linkage system has a connecting link, a clevis structure and two shock absorber assemblies. In some aspects, the forming of the cargo area structure at step 2502 may include pivotably mounting the connecting link to the seatback panel. In some aspects, the forming of the cargo area structure at step 2502 may include pivotably mounting a first portion of each of the four shock absorber assemblies to one of the two clevis structures, and pivotably mounting a second portion of each of the four shock absorber assemblies to one of the four front floor anchors.

[0090] FIGS. 26-29 show a crash test sled 700 that includes a linkage assembly 752 according to embodiments.

[0091] FIG. 26 is a perspective view of a crash test sled 700 that includes a roof assembly 733 mounted to the crash test sled 700 according to embodiments. In some embodiments, the roof assembly 733 is removable from the crash test sled 700 to make install easier and faster. As shown, the crash test sled 700. As shown, the crash test sled 700 includes a “pallet base” 725 (e.g., for quick change out) and a seatback mechanism assembly 726. As shown, the pallet base 725 includes a cargo area structure 724 including a floor, one or more tiedown anchors 740 mounted to the floor, a rear panel, and two sidewalls (e.g., a left sidewall and a right sidewall). As shown, the seatback mechanism assembly 726 includes a seatback panel 722, a front support frame 750, and a linkage assembly 752 supporting the seatback panel 722 and connected to the front support frame 750. In some aspects, the linkage assembly 752 may be utilized to adjust, modify, or otherwise control forces or movement in the crash test sled 700, such as to simulate, replicate, or mimic the actions of a second-row seatback in the event of a crash. In some aspects, the linkage assembly 752 may provide a leverage profile which compresses a spring a large amount in the beginning of the travel, and much less at the end, which gives the force profile, for example, described above with reference to FIG. 19 and below with reference to FIGS. 28 and 29. The crash test sled 700 may further include a sensor assembly (e.g., comprising one or more load cell sensors, cameras, or the like) configured to measure, calculate, or otherwise determine an impact force applied to the seatback panel 722 during an impact event.AP-24138-3520-WG000

[0092] FIG. 27 is an exploded view of the linkage assembly 752 of FIG. 26 according to embodiments. As shown, the seatback mechanism assembly 726 includes the seatback panel 722 and two front floor anchors 723A, 723B (including, but not limited to, one or more bottom mounts and pivot points), and the seatback panel 722 is pivotably mounted to the two front floor anchors 723A, 723B. As shown, the hnkage assembly 752 includes two linkage systems 754A, 754B.

[0093] As shown in FIG. 27, the hnkage system 754A includes a connecting link 760A pivotably mounted to the seatback panel 722 (e.g., via a first connector mounting structure, such as the connector mounting structure 721 shown in FIG. 28), a rocker link 762 A, a primary shock link 764A, a secondary shock link 766 A, a clevis structure 768 A, and two shock absorber assemblies 770 A, 770B (e.g., compression springs and dampers). As shown, each of the two shock absorber assemblies 770A, 770B includes a first portion (e.g., a proximal end) pivotably mounted to the clevis structure 768A and a second portion (e.g., a distal end) that is pivotably mounted to a front floor anchor 772A of the crash test sled 700. The secondary shock link 766A has a first end pivotably attached to the primary shock link 764A between the first and second ends of the primary shock link 764A, and in the illustrated embodiment is positioned closer to the first end of the primary shock link 764A (e.g., closer to the two shock absorber assemblies 770 A, 770B than to the rocker link 762 A). The secondary shock link 766Ahas a second end attached to the second fixed portion 767A of the crash test sled 700. The rocker link 762A has a first end pivotably attached to the primary shock link 764A and a second end pivotably attached to the first fixed portion 763A of the crash test sled 700. The connecting link 760A has a first end pivotably attached to the rocker link 762 A and a second end pivotably attached to the seatback panel 722. The connecting link 760A is attached to the rocker link 762A between the ends of the rocker link 762A, and in the illustrated embodiment is positioned closer to the first end of the rocker link 762A (e.g., closer to the primary shock link 764A than to the first fixed portion 763A).

[0094] As shown in FIG. 27, the hnkage system 754B includes a connecting link 760B pivotably mounted to the seatback panel 722 (e.g., via a second connectorAP-24138-3520-WG000 mounting structure, such as another of the connector mounting structure 721 shown in FIG. 28), a rocker link 762B, a primary shock link 764B, a secondary shock link 766B, a clevis structure 768B, and two shock absorber assemblies 770C, 770C (e.g., compression springs and dampers). As shown, each of the two shock absorber assemblies 770C, 770D includes a first portion (e.g., a proximal end) pivotably mounted to the clevis structure 768B and a second portion (e.g., a distal end) that is pivotably mounted to a front floor anchor 772B of the crash test sled 700. The secondary shock link 766B has a first end pivotably attached to the primary shock link 764B between the first and second ends of the primary shock link 764B, and in the illustrated embodiment is positioned closer to the first end of the primary shock link 764B (e.g., closer to the two shock absorber assemblies 770C, 770D than to the rocker link 762B). The secondary shock link 766B has a second end attached to the second fixed portion 767B of the crash test sled 700. The rocker link 762B has a first end pivotably attached to the primary shock link 764B and a second end pivotably attached to the first fixed portion 763B of the crash test sled 700. The connecting fink 760B has a first end pivotably attached to the rocker link 762B and a second end pivotably attached to the seatback panel 722. The connecting link 760B is attached to the rocker link 762B between the ends of the rocker link 762B, and in the illustrated embodiment is positioned closer to the first end of the rocker link 762B (e.g., closer to the primary shock link 764B than to the first fixed portion 763B).

[0095] FIGS. 28-29 are perspective and side views, respectively, of a linkage system 754 (e.g., linkage system 754A, linkage system 754B) of the linkage assembly 752 according to embodiments. As shown, the linkage system 754 may include a connecting link 760 pivotably mounted to the seatback panel 722 (e.g., via connector mounting structure 721 shown in FIG. 28), a rocker link 762, a primary shock link 764, a secondary shock link 766, a clevis structure 768, and a shock absorber assembly 770 (e.g., compression spring and damper). As shown, the shock absorber assembly 770 includes a first portion (e.g., a proximal end) pivotably mounted to the clevis structure 768 and a second portion (e.g., a distal end) that is pivotably mounted to a front floor anchor 772 of the crash test sled 700.AP-24138-3520-WG000

[0096] In some embodiments, as shown, the linkage system 754 utilizes four different links to manipulate the rate at which the spring in the shock absorber assembly 770 is compressed. In some aspects, a large impact force may be applied to the seatback panel 722 to move the seatback initially and the impact force may subsequently taper to a lesser impact force later in the seatback panel 722’s movement. Generally speaking, the linkage system 754 includes one or more pivotable hnks connecting the seatback panel 722 to the shock absorber assembly 770 in a manner that replicates the mounting of a seat in a vehicle, or the mounting of a seatback panel in the ECE R17 test (such as a shear pin designed to fail under a predetermined force, as discussed above with reference to the rear pivot mount 163A and the front pivot mount 163B). In various embodiments, the linkage system 754 includes one link, two hnks, three links, four links (as illustrated), five hnks, six hnks, or more. In various embodiments, the linkage system 754 includes a shear pin (not shown) configured to fail in response to an application of a predetermined impact force to the seatback panel 722, such as when the impact force applied to the seatback panel 722 during an impact event (e.g., crash) is greater than the predetermined impact force.

[0097] In some embodiments, as shown, a connecting hnk 760 attaches the seatback panel 722 to the rest of the linkage system 754, starting with the rocker link 762. In the illustrated embodiment, the links of the linkage system 754 are mounted with pivotable connections at each connection point. The rocker link 762 is pivotably connected to a first fixed portion 763 of the crash test sled 700. In some aspects, the rocker link 762 is configured to contribute to decreasing the amount of movement required of the springs of the shock absorber assembly 770 such that sourcing may be possible. The rocker link 762 then pushes on the primary shock link 764. The primary shock link 764 connects the linkage system 754 to the shock absorber assembly 770 by use of a clevis structure 768. The clevis structure 768 may be utilized to increase the overall length of the shock absorber assembly 770, to increase space for the dampers that will occupy space where the spring is located, and, in some aspects, to allow the use of, for example, two shock absorber assemblies 770 A, 770BAP-24138-3520-WG000(shown in FIG. 28) per clevis structure 768. In the illustrated embodiment shown in FIG. 28, a proximal end of each of the two shock absorber assemblies 770A, 770B is pivotably mounted to the crash test sled 700 at a front floor mounting structure 773 A, 773B, respectively, of the front floor anchor 772 and a distal end of each of the two shock absorber assemblies 770A, 770B is attached to a clevis mounting structure 769A, 769B, respectively, of the clevis structure 768. As a result, in some aspects (as shown in FIG. 27), a total of two clevis structures, four shock absorber assemblies, and four front floor anchors may be included in the crash test sled 700. In some embodiments, the clevis structure 768 does not substantially change the geometry of the links in the hnkage system 754, but rather provides a way for a spring to be longer than the space allotted but still attach to the same location as to not disturb the geometry of the system by conforming to the shock absorber assemblies or springs that are available. In some aspects, the movement of the primary shock link 764 is controlled by the secondary shock link 766 (also referred to as the “upper shock link”), which is connected to a second fixed portion 767 of the crash test sled 700. The secondary shock link 766 is configured to push the primary shock link 764 downwards and attain the predetermined force curve. It will be appreciated that one or more of the illustrated clevis structures may be substituted with other pivoting structures known in the art.

[0098] The linkage system 754 provides the various links and the shock absorber assembly 770 to be pivotably attached to the crash test sled 700, each other, and the seatback panel 722. In the illustrated embodiment, a proximal end of the shock absorber assembly 770 is pivotably mounted to the crash test sled 700 at the front floor anchor 772 and a distal end is attached to the clevis structure 768. The clevis structure 768 is attached to a first end of the primary shock link 764, and a second end of the primary shock link is pivotably attached to the rocker link 762. The secondary shock link 766 has a first end pivotably attached to the primary shock link 764 between the first and second ends, and in the illustrated embodiment is positioned closer to the first end of the primary shock link (i.e. closer to the shock absorber assembly 770 than to the rocker link 762). The secondary shock link 766 hasAP-24138-3520-WG000 a second end attached to the second fixed portion 767 of the crash test sled 700. The rocker link 762 has a first end pivotably attached to the primary shock link 764 and a second end pivotably attached to the first fixed portion 763 of the crash test sled 700. The connecting link 760 has a first end pivotably attached to the rocker link 762 and a second end pivotably attached to the seatback panel 722 (e.g., via connector mounting structure 721 shown in FIG. 28). The connecting link 760 is attached to the rocker link 762 between the ends of the rocker link, and in the illustrated embodiment is positioned closer to the first end of the rocker link 762 (e.g., closer to the primary shock link 764 than to the first fixed portion 763).

[0099] Referring generally to FIGS. 30-39, additional embodiments and / or components are shown. In these embodiments, the test sled 800 is comprised of a plurality of subassemblies that can be assembled and disassembled as modular components. The subassemblies generally include a pallet base 825, a seatback mechanism assembly 826, an upper structure assembly 828, a roof assembly 830, a cargo assembly 834 and a linkage assembly 836.

[0100] In some embodiments, the roof assembly 830 is removable from the rest of the test sled 800 to make installation easier and faster for the sled team. In certain embodiments, the roof assembly 830 incorporates similar tubing and design to the upper structure that is used on a conventional side impact bench. The illustrated roof assembly 830 uses a series of 2” by 6” rectangular steel pipes which create a rigid structure for placement of cameras on various camera mounts 892 to observe the crash event, and in the case of the present disclosure, act as the “roof’ of the cargo area in a car to observe the results of a loose kennel striking the roof. Weldments 904 of the roof assembly 830 and weldments 908 of the upper structure assembly 828 are bolted together via bolt holes 912, or otherwise releasable secured to each other, such that support legs 914 of the upper structure assembly 828 support respective cross beams 916 of the roof assembly. Likewise, the upper structure assembly 828 is bolted or otherwise releasably secured to the pallet base 825.

[0101] In some applications, the roof assembly 830 provides a mounting location for upper straps (e.g., upper strap mounts 895) used to mount an object in the vehiclecargo area. The strap mounts 895 can be adjustable to accommodate different loading configurations. Because the roof assembly 830 is separately removable, an alternate structure may be included to support the seatback assembly 826, cargo assembly 834, and hnkage assembly 836 which can stand alone of the sled. The roof assembly 830 and / or the upper structure assembly 828 can include one or more hoist points 922 for lifting the assemblies into position. The roof height of the structure may correspond to any vehicle roof, in certain embodiments the height corresponds to the tallest cargo area in a conventional vehicle, for example a full-size SUV such as the Chevrolet Tahoe. It will be appreciated that the modular features of the test sled 800 can be incorporated into any of the above-described embodiments to facilitate shipping and / or ease of assembly and disassembly and / or storage.

[0102] The disclosed embodiments of a crash test sled described herein may be implemented to evaluate various metrics and criteria. In some embodiments, a crate in the crash test sled may be evaluated for one or more of: amount of force transferred to the seatback, location(s) of force transferred to the seatback, deformation of the seatback, any contact with the seatback, overall structural integrity, forces and contact with ceiling, forces and contact with sides and / or rear hatch, crate door performance in staying closed, crate door performance in being operable post-crash, resulting sharp edges, and the like. Moreover, in embodiments, an animal test dummy may be placed in the crash test sled and / or containment device and evaluated for head gravitational forces (G-forces), head injury criterion (HIC) values, number of impacts, direction(s) of forces, remaining in the containment device, and the like. Accordingly, methods applicable to the present disclosure may include the step(s) of measuring and / or evaluating one or more of the aforementioned metrics and criteria.

[0103] It will be appreciated by those skilled in the art that changes may be made to the embodiments described above without departing from the disclosed concept thereof. It should further be appreciated that structural features and methods associated with one of the embodiments can be incorporated into other embodiments. It is understood, therefore, that this disclosure is not limited to the particularembodiment disclosed, but rather modifications are also covered within the scope of the present disclosure as defined by the appended claims.

[0104] The above-described bassinet assembly may be implemented in various configurations and operated with various methods which are listed below:1. A crash test sled for a rear cargo area of a vehicle, comprising: a cargo area structure comprising a floor, a wall, a seatback panel positioned forward of the floor, and a roof panel; and a sensor assembly, wherein the sensor assembly is configured to determine an impact force applied to the seatback panel during an impact event.2. The crash test sled of claim 1, the cargo area structure further comprising a front support frame supporting the seatback panel, the front support frame comprising a horizontal member connected to the seatback panel and extending forward of the seatback panel.3. The crash test sled of claim 2, the horizontal member comprising: a first pivot mount connected to the seatback panel by a first pivot pin; and a second pivot mount connected to another portion of the front support frame by a second pivot pin.4. The crash test sled of claim 3, one of the first pivot pin or the second pivot pin comprising a shear pin configured to fail when the impact force is greater than a predetermined impact force.5. The crash test sled of claim 2, the sensor assembly comprising a load sensor mounted to a surface of the horizontal member.6. The crash test sled of claim 1, the wall comprising one or more of a rear panel, a left sidewall, and a right sidewall.7. The crash test sled of claim 1, the wall comprising a backing frame, a support panel formed of metal, and a cover.8. The crash test sled of claim 1, the roof panel comprising a front portion and a rear portion, the rear portion having a lower height than the front portion.9. The crash test sled of claim 1, the cargo area structure further comprising a front floor anchor, the seatback panel being pivotably mounted to the front floor anchor.10. The crash test sled of claim 1, the cargo area structure further comprising a tiedown anchor, the tiedown anchor rated up to about 500 pounds (lbs).11. The crash test sled of claim 1, the cargo area structure further comprising two or more tiedown anchors positioned proximate to two or more corners of the floor.12. The crash test sled of claim 1, further comprising a weight device having a predetermined mass and configured to be positioned a predetermined distance rearward of the seatback panel.13. The crash test sled of claim 12, the predetermined mass being between about 15 kilograms (kg) and about 20 kg, and the predetermined distance being between about 175 millimeters (mm) and about 225 mm.14. The crash test sled of claim 12, further comprising a containment device positioned rearward of the seatback panel, the weight device being disposed within the containment device.15. The crash test sled of claim 1, further comprising upper strap mounts.16. The crash test sled of claim 15, the upper strap mounts being affixed to a rear portion of the roof panel.17. The crash test sled of claim 1, further comprising a hnkage assembly supporting the seatback panel.18. The crash test sled of claim 17, the hnkage assembly comprising a clevis structure and a shock absorber assembly.19. The crash test sled of claim 18, the shock absorber assembly comprising a first portion pivotably mounted to the clevis structure.20. The crash test sled of claim 19, the cargo area structure further comprising a front floor anchor, and the shock absorber assembly comprising a second portion pivotably mounted to the front floor anchor.21. The crash test sled of claim 17, the linkage assembly comprising a connecting link pivotably mounted to the seatback panel.22. A method of using a crash test sled for a rear cargo area of a vehicle, comprising: mounting a load sensor of a sensor assembly to a surface of a cargo area structure, the sensor assembly being configured to determine an impact force applied to a seatback panel of the cargo area structure during an impact event;disposing a containment device on a floor of the cargo area structure; placing a weight device in the containment device; and determining, by the sensor assembly, the impact force applied to the seatback panel during the impact event.23. A method of manufacturing a crash test sled for a rear cargo area of a vehicle, the method comprising: forming a cargo area structure comprising a floor, a seatback panel positioned forward of the floor, and a roof panel; and mounting a sensor assembly to the cargo area structure, wherein the sensor assembly is configured to determine an impact force applied to the seatback panel during an impact event.24. The method of claim 23, the forming the cargo area structure further comprising: forming the cargo area structure to further comprise a front support frame comprising a horizontal member extending forward of the seatback panel, the horizontal member comprising a first pivot mount at a first end of the horizontal member, and a second pivot mount at a second end of the horizontal member opposite the first end; mounting the first pivot mount of the horizontal member to the seatback panel by a first pivot pin; and mounting the second pivot mount of the horizontal member to another portion of the front support frame by a second pivot pin.25. The method of claim 24, the mounting the sensor assembly further comprising mounting a load sensor of the sensor assembly to a surface of the horizontal member.26. The method of claim 23, the forming the cargo area structure further comprising: forming the cargo area structure to further comprise a hnkage assembly and a front floor anchor, the hnkage assembly comprising a connecting link, a clevis structure, and a shock absorber assembly; mounting the connecting link pivotably to the seatback panel; mounting a first portion of the shock absorber assembly to the clevis structure; and mounting a second portion of the shock absorber assembly to the front floor anchor.27. The method of claim 26, the mounting the sensor assembly further comprising mounting a load sensor of the sensor assembly to a surface of the linkage assembly.28. The method of claim 23, the forming the cargo area structure further comprising forming the roof panel to have a front portion and a rear portion, the rear portion having a lower height than the front portion.29. The method of claim 23, the forming the cargo area structure further comprising: forming the cargo area structure to further comprise a front floor; and pivotably mounting the seatback panel to the front floor.30. A crash test sled for a rear cargo area of a vehicle, comprising: a cargo area structure comprising a floor, a seatback panel positioned forward of the floor; and a sensor assembly,wherein the sensor assembly is configured to determine an impact force applied to the seatback panel during an impact event; and a linkage assembly supporting the seatback panel.31. The crash test sled of claim 30, the linkage assembly comprising a clevis structure and a shock absorber assembly, and the shock absorber assembly comprising a first portion pivotably mounted to the clevis structure.32. The crash test sled of claim 31, the cargo area structure further comprising a front floor anchor, and the shock absorber assembly comprising a second portion pivotably mounted to the front floor anchor.33. The crash test sled of claim 30, the linkage assembly comprising a connecting link pivotably mounted to the seatback panel.34. The crash test sled of claim 30, further comprising a seatback subassembly removably mounted to the sled.35. The crash test sled of claim 34, wherein the seatback subassembly includes the seatback panel and the linkage assembly.36. The crash test sled of claim 30, wherein the cargo area structure further comprises a removable roof assembly.37. The crash test sled of claim 36, wherein the removable roof assembly includes a plurahty of strap mounts.38. The crash test sled of claim 36, wherein the cargo area structure incudes an upper structure assembly, wherein the removable roof assembly is bolted to the upper structure assembly, and the upper structure assembly is bolted to the floor.39. A crash test sled for a rear cargo area of a vehicle, comprising: a cargo area structure comprising a seatback panel; and a hnkage assembly comprising a shock absorber assembly, and one or more pivotable links connecting the seatback panel to the shock absorber assembly.40. The crash test sled of claim 39, the crash test sled further comprising a first fixed portion, a second fixed portion, and a front floor anchor positioned forward of the seatback panel, and the one or more pivotable links comprising a connecting fink pivotably mounted to the seatback panel, a rocker link pivotably connected to the connecting link and the first fixed portion of the crash test sled, a primary shock link pivotably connected to the rocker link, a secondary shock link pivotably connected to the primary shock link and the second fixed portion of the crash test sled, and a clevis structure pivotably connected to the primary shock link, the shock absorber assembly pivotably connected to the clevis structure and the front floor anchor of the crash test sled.41. The crash test sled of claim 39, the hnkage assembly further comprising a shear pin configured to fail in response to an application of a predetermined impact force to the seatback panel.

[0105] Having thus described the present embodiments in detail, it is to be appreciated and will be apparent to those skilled in the art that many physical changes, only a few of which are exemplified in the detailed description of the disclosure, could be made without altering the inventive concepts and principles embodied therein.

[0106] It is also to be appreciated that numerous embodiments incorporating only part(s) of the disclosed embodiments are possible which do not alter, with respect to those parts, the inventive concepts and principles embodied therein.The present embodiment and optional configurations are therefore to be considered in all respects as exemplary and / or illustrative and not restrictive, the scope of the disclosure being indicated by the appended claims rather than by the foregoing description, and all alternate embodiments and changes to this embodiment which come within the meaning and range of equivalency of said claims are therefore to be embraced therein.

Claims

CLAIMSWhat is claimed is:

1. A crash test sled for a rear cargo area of a vehicle, comprising: a cargo area structure comprising a floor, a wall, a seatback panel positioned forward of the floor, and a roof panel; and a sensor assembly, wherein the sensor assembly is configured to determine an impact force applied to the seatback panel during an impact event.

2. The crash test sled of claim 1, the cargo area structure further comprising a front support frame supporting the seatback panel, the front support frame comprising a horizontal member connected to the seatback panel and extending forward of the seatback panel.

3. The crash test sled of claim 2, the horizontal member comprising: a first pivot mount connected to the seatback panel by a first pivot pin; and a second pivot mount connected to another portion of the front support frame by a second pivot pin.

4. The crash test sled of claim 3, one of the first pivot pin or the second pivot pin comprising a shear pin configured to fail when the impact force is greater than a predetermined impact force.

5. The crash test sled of claim 2, the sensor assembly comprising a load sensor mounted to a surface of the horizontal member.

6. The crash test sled of claim 1, the wall comprising one or more of a rear panel, a left sidewall, and a right sidewall.

7. The crash test sled of claim 1, the wall comprising a backing frame, a support panel formed of metal, and a cover.

8. The crash test sled of claim 1, the roof panel comprising a front portion and a rear portion, the rear portion having a lower height than the front portion.

9. The crash test sled of claim 1, the cargo area structure further comprising a front floor anchor, the seatback panel being pivotably mounted to the front floor anchor.

10. The crash test sled of claim 1, the cargo area structure further comprising a tiedown anchor, the tiedown anchor rated up to about 500 pounds (lbs).

11. The crash test sled of claim 1, the cargo area structure further comprising two or more tiedown anchors positioned proximate to two or more corners of the floor.

12. The crash test sled of claim 1, further comprising a weight device having a predetermined mass and configured to be positioned a predetermined distance rearward of the seatback panel.

13. The crash test sled of claim 12, the predetermined mass being between about 15 kilograms (kg) and about 20 kg, and the predetermined distance being between about 175 millimeters (mm) and about 225 mm.

14. The crash test sled of claim 12, further comprising a containment device positioned rearward of the seatback panel, the weight device being disposed within the containment device.

15. The crash test sled of claim 1, further comprising upper strap mounts.

16. The crash test sled of claim 15, the upper strap mounts being affixed to a rear portion of the roof panel.

17. The crash test sled of claim 1, further comprising a hnkage assembly supporting the seatback panel.

18. The crash test sled of claim 17, the hnkage assembly comprising a clevis structure and a shock absorber assembly.

19. The crash test sled of claim 18, the shock absorber assembly comprising a first portion pivotably mounted to the clevis structure.

20. The crash test sled of claim 19, the cargo area structure further comprising a front floor anchor, and the shock absorber assembly comprising a second portion pivotably mounted to the front floor anchor.

21. The crash test sled of claim 17, the linkage assembly comprising a connecting link pivotably mounted to the seatback panel.

22. A method of using a crash test sled for a rear cargo area of a vehicle, comprising: mounting a load sensor of a sensor assembly to a surface of a cargo area structure, the sensor assembly being configured to determine an impact force applied to a seatback panel of the cargo area structure during an impact event; disposing a containment device on a floor of the cargo area structure; placing a weight device in the containment device; anddetermining, by the sensor assembly, the impact force applied to the seatback panel during the impact event.

23. A method of manufacturing a crash test sled for a rear cargo area of a vehicle, the method comprising: forming a cargo area structure comprising a floor, a seatback panel positioned forward of the floor, and a roof panel; and mounting a sensor assembly to the cargo area structure, wherein the sensor assembly is configured to determine an impact force applied to the seatback panel during an impact event.

24. The method of claim 23, the forming the cargo area structure further comprising: forming the cargo area structure to further comprise a front support frame comprising a horizontal member extending forward of the seatback panel, the horizontal member comprising a first pivot mount at a first end of the horizontal member, and a second pivot mount at a second end of the horizontal member opposite the first end; mounting the first pivot mount of the horizontal member to the seatback panel by a first pivot pin; and mounting the second pivot mount of the horizontal member to another portion of the front support frame by a second pivot pin.

25. The method of claim 24, the mounting the sensor assembly further comprising mounting a load sensor of the sensor assembly to a surface of the horizontal member.

26. The method of claim 23, the forming the cargo area structure further comprising: forming the cargo area structure to further comprise a linkage assembly and a front floor anchor, the linkage assembly comprising a connecting link, a clevis structure, and a shock absorber assembly; mounting the connecting link pivotably to the seatback panel; mounting a first portion of the shock absorber assembly to the clevis structure; and mounting a second portion of the shock absorber assembly to the front floor anchor.

27. The method of claim 26, the mounting the sensor assembly further comprising mounting a load sensor of the sensor assembly to a surface of the linkage assembly.

28. The method of claim 23, the forming the cargo area structure further comprising forming the roof panel to have a front portion and a rear portion, the rear portion having a lower height than the front portion.

29. The method of claim 23, the forming the cargo area structure further comprising: forming the cargo area structure to further comprise a front floor; and pivotably mounting the seatback panel to the front floor.

30. A crash test sled for a rear cargo area of a vehicle, comprising: a cargo area structure comprising a floor, a seatback panel positioned forward of the floor; and a sensor assembly, wherein the sensor assembly is configured to determine an impact force applied to the seatback panel during an impact event; anda linkage assembly supporting the seatback panel.

31. The crash test sled of claim 30, the linkage assembly comprising a clevis structure and a shock absorber assembly, and the shock absorber assembly comprising a first portion pivotably mounted to the clevis structure.

32. The crash test sled of claim 31, the cargo area structure further comprising a front floor anchor, and the shock absorber assembly comprising a second portion pivotably mounted to the front floor anchor.

33. The crash test sled of claim 30, the linkage assembly comprising a connecting link pivotably mounted to the seatback panel.

34. The crash test sled of claim 30, further comprising a seatback subassembly removably mounted to the sled.

35. The crash test sled of claim 34, wherein the seatback subassembly includes the seatback panel and the linkage assembly.

36. The crash test sled of claim 30, wherein the cargo area structure further comprises a removable roof assembly.

37. The crash test sled of claim 36, wherein the removable roof assembly includes a plurality of strap mounts.

38. The crash test sled of claim 36, wherein the cargo area structure incudes an upper structure assembly, wherein the removable roof assembly is bolted to the upper structure assembly, and the upper structure assembly is bolted to the floor.

39. A crash test sled for a rear cargo area of a vehicle, comprising:a cargo area structure comprising a seatback panel; and a linkage assembly comprising a shock absorber assembly, and one or more pivotable links connecting the seatback panel to the shock absorber assembly.

40. The crash test sled of claim 39, the crash test sled further comprising a first fixed portion, a second fixed portion, and a front floor anchor positioned forward of the seatback panel, and the one or more pivotable links comprising a connecting fink pivotably mounted to the seatback panel, a rocker link pivotably connected to the connecting link and the first fixed portion of the crash test sled, a primary shock link pivotably connected to the rocker link, a secondary shock link pivotably connected to the primary shock link and the second fixed portion of the crash test sled, and a clevis structure pivotably connected to the primary shock link, the shock absorber assembly pivotably connected to the clevis structure and the front floor anchor of the crash test sled.

41. The crash test sled of claim 39, the bnkage assembly further comprising a shear pin configured to fail in response to an application of a predetermined impact force to the seatback panel.

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