Patent Description:
Automotive, aviation, and other vehicle manufacturers conduct a wide variety of collision testing to measure the effects of a collision on a vehicle and its occupants. Through collision testing, sometimes otherwise referred to as crash testing, a vehicle manufacturer gains valuable information that can be used to improve the vehicle for better occupant protection.

Collision testing often involves the use of anthropomorphic test device ("ATD"), sometimes alternatively referred to as anthropomorphic mannequins, and better known as "crash test dummies", to estimate a human's injury risk. The anthropomorphic test device typically includes a head assembly, spine assembly, rib cage assembly, pelvis assembly, right and left arm assemblies, and right and left leg assemblies. Joints are provided to couple various assemblies together and to allow articulation that simulates the human range of motion. In addition, these assemblies are typically covered with a simulated flesh that includes an inner foam material covered with a skin. The anthropomorphic test device must possess the general mechanical properties, masses, joints, and joint stiffness of the humans of interest. In addition, the ATD must possess sufficient mechanical impact response to cause them to interact with the vehicle's interior in a human-like manner during the collision testing.

In the pelvis assembly region of ATDs, during collision testing, it is desirable to have a proper pelvis assembly compression that replicates the seat height of an occupant in a vehicle, especially the hip joint height of the occupant relative to the vehicle seat. In particular, the hip joint height can influence a seat belt route that affects the ATD kinematics and submarining response of the pelvis, especially in reclined seating postures, which is popular with further autonomous vehicles ("AV"s).

In most current designs, different materials such as foams have been used to soften the pelvis flesh stiffness of the pelvis member of the pelvis assembly in an attempt to achieve a proper buttock compression of the pelvis assembly via the pelvis member in the ATD design. However, a proper buttock compression of the pelvis assembly via the pelvis member to simulate a human response has not been achieved, even with the use of low density foams.

Document <CIT> discloses an anthropomorphic test device utilizing a mounting mechanism for coupling a hollow member including a simulated flesh to a support structure, with the simulated flesh including a foam core portion covered with a skin portion.

The present invention addresses and minimizes or overcomes the compression issues associated with the prior art designs and provides therefore an anthropomorphic test device having a more human-like response during collision testing.

The present invention provides an anthropomorphic test device that includes a pelvis member. as defined in independent claim <NUM>. The present invention also relates to a method of simulating a human like response for a pelvis member of an anthropomorphic test device as defined in independent method claim <NUM>.

The pelvis member has a foam core and includes an abdomen region defining a first cavity and a pair of thigh regions extending from the abdomen region. The pelvis member also includes a buttock region positioned below the abdomen region and rearward of the pair of thigh regions. The buttock region defines a buttock cavity separate from the first cavity with the buttock region also defining at least one vent port. The anthropomorphic test device also includes a structural member positioned within the first cavity. The buttock cavity compresses from an open condition to a collapsed condition when the anthropomorphic test device is placed onto a surface for approximating a force applied by a body weight of a human.

Other features and advantages of the present invention will be readily appreciated, as the same becomes better understood, after reading the subsequent description taken in conjunction with the accompanying drawings.

Referring to <FIG> and <FIG>, embodiments of a portion of an anthropomorphic test device, or crash test dummy, in accordance with the subject invention is generally indicated at <NUM> and includes an abdomen component <NUM> coupled to a pelvis member <NUM>. The embodiments also preferably include a resilient flange <NUM> that is coupled to and extends from the pelvis member <NUM>. The abdomen component <NUM>, pelvis member <NUM> and resilient flange <NUM> are positioned on the anthropomorphic test device <NUM> in the embodiments herein in a position generally corresponding to the abdominal and abdomen region of the anthropomorphic test device <NUM>. <FIG> is also illustrated as an additional view of an anthropomorphic device in accordance with the prior art and does not include a buttock cavity <NUM> that is included in the embodiment of <FIG> and <FIG>, described further below.

The terms "anthropomorphic test device" or "crash test dummy" or "ATD" are used interchangeably in the present disclosure. The anthropomorphic test device <NUM> illustrated in the FIGS. is of a fiftieth percentile (<NUM>%) male type and is illustrated in a sitting position. This anthropomorphic test device <NUM> is used primarily to test the performance of automotive interiors and restraint systems for adult front and rear seat occupants. The size and weight of the anthropomorphic test device <NUM> are based on anthropometric studies, which are typically done separately by the following organizations, University of Michigan Transportation Research Institute (UMTRI), U. Military Anthropometry Survey (ANSUR), and Civilian American and European Surface Anthropometry Resource (CESAR). It should be appreciated that ranges of motions, centers of gravity, and segment masses simulate those of human subjects defined by the anthropometric data.

The abdomen component <NUM> includes a foam core <NUM> that is typically covered with a skin <NUM>. The abdomen component <NUM> allows for the inclusion of a structural member <NUM>, which fills a gap generated between the rib cage and the abdomen when seating the ATD <NUM> in a reclined posture.

The abdomen component <NUM> includes an upper portion <NUM> that is configured to be positioned between beneath a rib cage assembly (not shown) and a lower portion <NUM> that is configured to be received within the pelvis member <NUM>.

The lower portion <NUM> of the abdomen component <NUM> includes a first portion <NUM> and a second portion <NUM>. The second portion <NUM>, here shown as an upper band region <NUM>, is positioned adjacent to and extends away from the upper portion <NUM> towards the first portion <NUM>. The outer surface <NUM> of the second portion <NUM> has a length defined between the first portion <NUM> and the upper portion <NUM>. An edge defining a notch <NUM> extends transversely to and connects the second portion <NUM> to the upper portion <NUM>.

The first portion <NUM> extends from the second portion <NUM> in a direction opposite the upper portion <NUM> and terminates into a bottom region <NUM>. The outer surface <NUM> of the first portion <NUM> extends inwardly relative to the outer surface <NUM> of the second portion <NUM> and terminates into a bottom region <NUM>. The bottom region <NUM> may include one or more projection regions <NUM>.

The maximum width of the first portion <NUM> of the abdomen component <NUM> is less than the maximum width of the second portion <NUM>. The maximum width of the first portion <NUM> refers to a distance measurement between the outer surfaces <NUM> of the first portion <NUM> of the abdomen component <NUM>, while the maximum width of the second portion <NUM> refers to a distance measurement between the outer surfaces <NUM> of the second portion <NUM> of the abdomen component <NUM> along any one cross-sectional view of the abdomen member, which the line defining each of the respective widths being parallel to one another. It can be appreciated that by changing the plane of the cross-sectional view of the abdomen component, additional maximum widths can be obtained. If enough different cross-sectional views of the abdomen component are obtained, the plurality of obtained maximum widths can define a respective circumference for each of the first portion <NUM> and second portion <NUM> of the abdomen component <NUM>. Notably, because the maximum width of the first portion <NUM> of the abdomen component <NUM> is less than the maximum width of the second portion <NUM>, the corresponding circumference of the first portion <NUM> of the abdomen component <NUM> is also less than the corresponding circumference of the second portion <NUM>.

The pelvis member <NUM>, like the abdomen component <NUM>, includes a foam core <NUM> that is typically covered with a skin <NUM>. The skin <NUM> may envelop the foam core <NUM>, and thus the skin <NUM> defines a foam-containing cavity portion <NUM> (i.e., an inner cavity portion <NUM>) that contains the foam core <NUM>.

The pelvis member <NUM> includes an abdomen region <NUM> and a pair of thigh regions <NUM>, <NUM> extending from the abdomen region <NUM>. The pelvis member <NUM> also includes a buttock region <NUM> positioned below the abdomen region <NUM> and rearward of each of the thigh regions <NUM>, <NUM> (see <FIG> which illustrates schematically with brackets each of the regions <NUM>, <NUM>, <NUM>, and <NUM>). When the anthropomorphic test device <NUM> is positioned onto a surface <NUM>, the skin <NUM> of the buttock region <NUM> of the pelvis member <NUM> is positioned adjacent to and preferably in contact with surface <NUM>. While the surface <NUM> illustrated in <FIG> is the surface of sled buck used in the evaluation of anthropomorphic test devices <NUM> during certain collision test, the pelvis member <NUM> may be positioned onto any other kind of surface <NUM> that is used in the evaluation of anthropomorphic test devices <NUM>, such as a vehicle seat, a seat, a floor, or any other kind of structure having a surface <NUM> that is capable of receiving the anthropomorphic test device <NUM> placed thereon. As used hereinafter, the surface <NUM> may refer to any of the kinds of surfaces described above, and in particular to surfaces <NUM> wherein the anthropomorphic test device <NUM> is placed (such as seated) for subsequent testing such as collision testing.

As will be described in further detail below in <FIG> and <FIG>, the buttock region <NUM> defines a buttock cavity <NUM> that is capable of being compressed/collapsed (i.e., simulated buttock compression) to approximate the force applied with the body weight of a human seated upon the surface <NUM> prior to collision testing, which allows the anthropomorphic test device <NUM> to more closely simulates the performance of the pelvis member of a human during impact conditions associated with a crash such as a crash while seated on a vehicle seat of a vehicle such as a car. More in particular, the foam core <NUM> of the buttock region <NUM> defines, or partially defines in conjunction with the skin <NUM>, the buttock cavity <NUM> as described above.

The abdomen region <NUM> is open and includes a base inner surface <NUM> defining an opening <NUM> and defining an inner cavity <NUM>, or first cavity <NUM>, with the inner surface <NUM> contoured to correspond to the shape of the first portion <NUM> of the abdomen component <NUM>. The base inner surface <NUM> near the bottom of the first cavity <NUM> thus includes one or more surface depressions <NUM>, with each of the one or more surface depressions <NUM> configured to receive a corresponding one of the one or more projection regions <NUM> when the abdomen component <NUM> is received within the first cavity <NUM>, as will be described further below.

The first cavity <NUM> allows for the inclusion of a support member <NUM>, here shown as pelvis support member <NUM>, that is intended to simulate the lower portion of a human spine to support the abdomen from below. Notably, the first cavity <NUM> is distinct and separate from the buttock cavity <NUM> (i.e., they are not fluidically connected). The support member <NUM>, in certain instances, may be coupled to a further support structure <NUM> (i.e., an additional support structure <NUM>), shown in <FIG> as pair of thigh support structures <NUM>.

An inner surface of the skin <NUM> of the thigh regions <NUM>, <NUM> defines respective openings <NUM>, <NUM> configured to receive additional members associated with the legs of the crash dummy <NUM>, including the lower thigh members (not shown), and accommodates the additional structural members <NUM> that extend from and are positioned adjacent to or coupled to the structural member <NUM>. The openings <NUM>, <NUM> extend in a direction towards the abdomen region <NUM> and are fluidically coupled with the first cavity <NUM>. Accordingly, in addition to the first cavity <NUM>, the openings <NUM>, <NUM> are also distinct and separate from the buttock cavity <NUM>.

The anthropomorphic test device <NUM> also includes a resilient flange <NUM> which is coupled to the pelvis member <NUM>. The resilient flange <NUM> includes a flange inner surface <NUM> and an opposing flange outer surface <NUM>, with a peripheral edge <NUM> of the resilient flange <NUM> opposite the pelvis member <NUM> connecting the flange inner and outer surface, with the flange inner surface <NUM> further defining the opening <NUM> and additionally defining a second cavity <NUM>. The second cavity <NUM> is in open communication with the first cavity <NUM> of the pelvis member <NUM>. The flange inner surface <NUM> is sized and shaped to generally correspond to the size and shape of the outer surface <NUM> of the upper band region <NUM> of the abdomen component <NUM>. The thickness of the resilient flange <NUM>, as measured between the flange inner surface <NUM> and the flange outer surface <NUM> (i.e., the length of the peripheral edge <NUM>), is thin, ranging generally from <NUM> to <NUM> millimeters, and more preferably from <NUM> to <NUM> millimeters, to provide the resilient flange <NUM> with flexibility such that it can resiliently be retained against the second portion <NUM> of the abdomen component <NUM>, as will be described further below. Preferably, the thickness of the resilient flange <NUM> corresponds to the transverse length of the notch <NUM>.

The resilient flange <NUM> also can be defined by a maximum width. The maximum width of the resilient flange <NUM>, and preferably the flange inner surface <NUM>, is defined prior to the second portion <NUM> of the abdomen component <NUM> being contained within the second cavity <NUM> and thus represents the maximum width of the flange inner surface <NUM> in the natural, or unstretched state. As shown, herein, the maximum width of the resilient flange <NUM> is less than the maximum width of the second portion <NUM> of the abdomen member <NUM> but is greater than the maximum width of the first portion <NUM> of the abdomen member <NUM>.

In certain embodiments, the resilient flange <NUM> is integrally formed with the pelvis member <NUM>, while in alternative embodiments the resilient flange <NUM> is a separate structure that is coupled to, or otherwise secured or affixed to, the pelvis member <NUM>. Like the abdomen component <NUM> and pelvis member <NUM>, the resilient flange <NUM> includes a skin <NUM>. However, unlike the abdomen component <NUM> and pelvis member <NUM>, the resilient flange <NUM> does not include a foam core contained within the skin <NUM>. The skin <NUM> may be formed from a single material or combination of materials that has the desired flexibility and/or elasticity and strength to perform its desired function, as described further below.

In certain embodiments, the resilient flange <NUM> extends from, or is otherwise integrally formed with the skin <NUM> of the pelvis member <NUM> and has a length terminating at the peripheral edge <NUM>. Accordingly, in these embodiments, the skin <NUM> may be an extension (i.e., is integrally formed with) of the skin <NUM> of the pelvis member <NUM> while in alternative embodiments the skin <NUM> is coupled to, affixed, or otherwise secured to and thus extends from the skin <NUM>.

Preferably, the length of the resilient flange <NUM>, from the pelvis member <NUM> to the peripheral edge <NUM>, is substantially like, or the same as, as the length of the second portion <NUM> of the abdomen component <NUM>. Further, the thickness of the skin <NUM> of the resilient flange <NUM>, may be the same or different as to the thickness of the skin <NUM>, and may range from <NUM> to <NUM> millimeters, and more preferably ranges from <NUM> to <NUM> millimeters.

When the abdomen component <NUM> is coupled to the pelvis member <NUM>, as shown in <FIG> and <FIG>, the second portion <NUM> of the abdomen component <NUM> is inserted within the opening <NUM> such that the abdomen component <NUM> is partially contained within the first cavity <NUM> and the second cavity <NUM> such that the outer surface <NUM> of the first portion <NUM> of the abdomen component <NUM> is engaged with the base inner surface <NUM>. In addition, the outer surface <NUM> of the second portion <NUM> of the abdomen component <NUM> is directly engaged with the outer surface <NUM> of the second portion <NUM>, and thus the abdomen component <NUM> is resiliently retained by the resilient flange <NUM>. Further, the peripheral edge <NUM> or the resilient flange <NUM> abuts the notch <NUM>, and thus the flange outer surface <NUM> transitions smoothly into the outer surface of the upper portion <NUM>.

Still further, each respective one of the projection regions <NUM> is seated within a corresponding one of the one or more surface depressions <NUM>. Even still further, the structural member <NUM> disposed within the abdomen component <NUM> is coupled to another structural member <NUM> contained in the first cavity <NUM> of the pelvis member <NUM>.

As the abdomen component <NUM> is being coupled to the pelvis member <NUM>, the first portion <NUM> of the abdomen component freely extends through the opening <NUM> and second cavity <NUM> and into the first cavity <NUM> because the maximum width of the first portion <NUM> is less than the maximum width of the resilient flange <NUM>. As the abdomen component <NUM> moves closer to the one or more surface depressions <NUM>, the second portion <NUM> of the abdomen component <NUM> contacts the flange inner surface <NUM> and begins to apply force to the flange inner surface <NUM> to stretch the skin <NUM> in a direction outwardly from the second cavity <NUM> and towards the flange outer surface <NUM>. This application of force increases the width of the resilient flange <NUM> beyond its maximum width to a width slightly greater than the maximum width of the second portion <NUM> of the abdomen component <NUM>, thus allowing the second portion <NUM> of the abdomen component to be fully received in the second cavity <NUM> with the outer surface <NUM> of the second portion <NUM> of the abdomen component <NUM> positioned into direct engagement with the flange inner surface <NUM>. Once the abdomen component is fully seated such that the one of the projection regions <NUM> are seated within a corresponding one of the one or more surface depressions <NUM> and such that the peripheral edge <NUM> abuts the notch <NUM>, the resiliency of the skin <NUM> retains the flange inner surface <NUM> of the resilient flange in direct engagement with the outer surface <NUM> of the second portion <NUM>. This direct engagement is sufficiently strong to retain the pelvis member <NUM> in the coupled state with the abdomen component <NUM>.

In this arrangement, the resilient flange <NUM> aids in initially positioning and maintaining the positioning of the abdomen component <NUM>, preferably by being resiliently retained against the outer surface <NUM> of the second portion <NUM>, within the cavity <NUM> of the pelvis member <NUM> prior to any collision testing. In addition, the resilient flange <NUM> aids in minimizing or preventing separation issues between the abdomen component <NUM> and the pelvis member <NUM> that may occur during collision testing by virtue of its resilient retention features, as compared with arrangements wherein the resilient flange <NUM> is not present.

Referring now to <FIG> and <FIG>, the present invention introduces the buttock cavity <NUM>, as described above, defined by the buttock region <NUM> of the pelvis member <NUM> that is sized and shaped to allow proper buttock compression of the buttock region <NUM> of the pelvis member <NUM> that simulates the response of a buttocks region of a human occupant seated upon the surface <NUM> (see <FIG> and <FIG>). When the anthropomorphic test device <NUM> is positioned onto the surface <NUM>, the buttock cavity <NUM> is compressed from an open condition (see <FIG> and <FIG>) to a collapsed condition (see <FIG> and <FIG>), with the compression more closely approximating the force applied by the body weight of a human seated upon the surface <NUM> as compared with a pelvis member of similar size shape and formed from the same materials but not including the buttock cavity <NUM>.

In certain embodiments, such as shown in <FIG> and <FIG>, the buttock cavity <NUM> is contained within the foam-containing cavity portion <NUM> and is entirely defined by the foam core <NUM> of the buttock region <NUM>. In other words, the buttock cavity <NUM> is surrounded by the foam core <NUM> (other than where the vent ports <NUM> are located) and is spaced from the skin <NUM>.

In certain alternative embodiments (not shown), the buttock cavity <NUM> is contained within the foam-containing cavity portion <NUM> but is partially defined by the foam core <NUM> and by an interior surface 44A of the skin <NUM>. In other words, the buttock cavity <NUM> is surrounded by the interior surface 44A of the skin <NUM> towards the outside of the pelvis member <NUM> and the foam core <NUM> towards the interior of the pelvis member <NUM>.

In either embodiment the buttock cavity <NUM> has a predefined width W1 and height H1, with the width W1 measured generally in a direction parallel to the length of the skin <NUM> located on the buttock region <NUM> that is positioned adjacent to the surface <NUM> and the height H1 measured in a direction normal to the width W1. The predefined height H1 factors in the normal compression of the buttock cavity <NUM> corresponding to the force applied by the body weight of the anthropomorphic test device <NUM> immediately prior to the anthropomorphic test device <NUM> being seated upon the surface <NUM>. This predefined height H1 may alternatively be referred to as an open condition for the buttock cavity <NUM> represented in <FIG> and <FIG>.

The buttock cavity <NUM> includes at least one vent port <NUM> (see <FIG>) extending through the foam-containing cavity portion <NUM> to the skin <NUM>. Stated another way, the buttock region <NUM> defines the buttock cavity <NUM> and also defines the at least one vent port <NUM>. The skin <NUM> typically includes openings <NUM> that extend from the vent ports <NUM> (and thus the openings <NUM> may be considered an extension of the vent port <NUM> or are otherwise may be considered to be partially defined by the vent ports <NUM>). Thus, the at least one vent port <NUM>, alone or in conjunction with the respective openings <NUM>, provides a passageway for air to travel to or from the buttock cavity <NUM> when seating the anthropomorphic test device <NUM> on the surface <NUM> or when removing the anthropomorphic test device <NUM> from the surface <NUM>.

While the at least one vent port <NUM> as illustrated in <FIG> are shown as being coordinated with the respective at least one opening <NUM> in the skin <NUM> and being open to the atmosphere surrounding the anthropomorphic test device <NUM>, in other embodiments the at least one vent port <NUM> may be vented to the atmosphere in areas not covered by the skin <NUM> (and thus not through a respective opening <NUM>). Still further, in other embodiments, the at least one vent port <NUM> may open internally to another region within the pelvis member <NUM> or internally within another region of the anthropomorphic test device <NUM> separate from the first cavity <NUM> that includes the pelvis support member <NUM> and may also include the thigh support structures <NUM>, and not be open otherwise to the atmosphere surrounding the pelvis member <NUM> or the anthropomorphic test device <NUM>.

In certain embodiments, such as shown in the <FIG>, the buttock cavity <NUM> includes two vent ports <NUM> spaced apart from each other, with corresponding openings <NUM> extending from each respective one of the two vent ports <NUM> through the skin <NUM>.

In certain embodiments, as best shown in <FIG> and <FIG>, the anthropomorphic test device <NUM> may include a jacket <NUM> coupled around the pelvis member <NUM> that includes a front portion <NUM> that is positioned adjacent to a front of the pelvis member <NUM> and a rear portion <NUM> that is positioned adjacent to a rear of the pelvis member <NUM> and side portions <NUM> connecting the front and rear portion <NUM>, <NUM>. While not shown, and similar to a human jacket or shirt, the top portion of the jacket (not shown) is closed and is secured over the shoulders of the anthropomorphic test device <NUM> but includes a central opening through which the dummy head extends (and is attached to the spine) and arm openings adjacent the intersection of the top portion and side portions <NUM> through which the dummy arms extend (and are attached to the spine). The positioning of the jacket <NUM> onto the anthropomorphic device <NUM>, in general, functions to maintain each of the components of anthropomorphic test device <NUM> between the head and legs in position prior to and during a subsequent collision impact test on the vehicle seat.

As also shown in <FIG> and <FIG> in addition to being best shown <FIG> and <FIG>, the jacket <NUM> includes a strap <NUM> that extends between the pair of thigh regions <NUM>, <NUM> from the front portion <NUM> of the jacket <NUM> (see FIB. 9A) to the rear portion <NUM> of the jacket <NUM> (see <FIG>). and which is coupled against and around the buttock region <NUM> of the pelvis member <NUM>. The strap <NUM> as illustrated is stitched to the front portion <NUM> of the jacket <NUM> and is secured onto the back portion <NUM> of the jacket using a hook and loop fastener system (shown in phantom generically as <NUM>). In alternative embodiments (not shown), the arrangement of the attachment of the strap <NUM> to the front portion <NUM> and rear portion <NUM> could be reversed, in which the strap <NUM> is sticked to the rear portion <NUM> and in which the hook and look fastening portion <NUM> secures the strap <NUM> to the front portion <NUM> of the jacket <NUM>. Still further, as opposed to being stitched to other the front or rear portion <NUM>, <NUM> of the jacket <NUM>, the strap <NUM> could simply be an extension of the material of the front or rear portion <NUM>, <NUM> of the jacket <NUM>.

The strap <NUM>, in any of the embodiments described above, functions to keep the pelvis member <NUM> properly positioned onto the surface <NUM> (as best shown in <FIG> and <FIG>) to allow for the proper buttock compression of the pelvis member via the collapse of the buttock cavity <NUM> from the open condition to the collapsed condition (as described below) such that the anthropomorphic test device <NUM> closely simulates a human response during a subsequent collision impact test on the vehicle seat.

When the anthropomorphic test device <NUM> is positioned on the surface <NUM>, the force caused by the weight of the anthropomorphic test device <NUM> downward onto the surface <NUM> through the buttock region <NUM> of the pelvis member <NUM> causes the buttock cavity <NUM> to compress from the open condition as shown in <FIG> and <FIG> to the collapsed condition as shown in <FIG> and <FIG>, with air escaping from the buttock cavity <NUM> through the at least one vent port <NUM> and, in certain embodiments, through the corresponding openings <NUM> in the skin <NUM>, which remain open in the open condition and collapsed condition and in every operating condition between the collapsed condition and the open condition. Stated another way, the at least one vent port <NUM> remains open for flow of air in each of the open and collapsed conditions. In the collapsed condition, the width W1 is generally maintained as in the open condition, but the height of a portion, or the entirety of, the buttock cavity <NUM> is reduced from the height H1 to a height H2.

In certain embodiments during the collapsed condition, the height H2 of a portion, or the entirety of, the buttock cavity <NUM> may be reduced to zero, wherein the foam core <NUM> immediately above and immediately below the buttock cavity <NUM> along the respective portion or entirety are brought into contact with each other.

In certain alternative embodiments, the height H2 of a portion, or the entirety of, the buttock cavity <NUM> may be reduced but is greater than zero, wherein the foam core <NUM> immediately above and immediately below the buttock cavity <NUM> along the respective portion or entirety are not brought into contact with each other but wherein the distance between them is reduced.

When the anthropomorphic test device <NUM> is not seated on a surface <NUM>, or where the pelvis member <NUM> is removed from the surface <NUM> or is otherwise not loaded by its own body weight or other form of loading force onto an object to which it is seated upon, the resiliency of the foam core <NUM> allows the pelvis member <NUM> to substantially return its normal shape (i.e., expand) when not seated upon the surface <NUM>, which allows the buttock cavity <NUM> to return to the open condition having the height H1 (returning from the height H2) and with air returning to the buttock cavity <NUM> through the openings <NUM>, when utilized, and through the vent ports <NUM> as the buttock cavity is expanded in height back towards H1 to aid in returning to the normal shape. The anthropomorphic test device <NUM> including the pelvis member <NUM> having the buttock cavity <NUM> may then be available for subsequent crash test simulations by being repositioned onto another surface <NUM> as desired (i.e., the anthropomorphic test device <NUM> is reusable).

The introduction of the buttock cavity <NUM> defined within the buttock region <NUM> of the pelvis member <NUM> allows the anthropomorphic test device <NUM> to approximate the seating height of the human pelvis more closely in a more representative position seated upon the surface of a vehicle seat with a lap belt being in contact with the pelvis and thigh as compared with pelvis members of similar size, shape, and construction but not including the buttock cavity (such as shown in <FIG>). This may allow for improvements in the design of vehicles for safely transporting occupants and to protect occupants during particular types of crashes. In particular, the compression of the pelvis member <NUM> including the buttock cavity <NUM> and at least one vent port <NUM> to the collapsed position when seated upon the surface <NUM> more closely simulates the corresponding buttock compression of a human when seated onto the same surface <NUM> as compared to a pelvis member not including such features. Replicating the seat height, and hip joint height, can influence the ATD kinematics and submarining response of the pelvis to simulate a human response more closely, especially in reclined seating postures, which is popular with further autonomous vehicles ("AV"s).

The buttock cavity <NUM> is formed in conjunction with the formation of the pelvis member <NUM>. In particular, a mold (not shown) is provided that is sized and shaped to correspond to the size and shape of the pelvis member <NUM>. The mold includes an insert <NUM> (see <FIG>) that is positioned within the cavity portion of the mold which is sized and shaped to correspond to the desired shape of the buttock cavity <NUM>, including the vent ports <NUM> and openings <NUM>.

To form the pelvis member <NUM> having the buttock cavity <NUM> in accordance with the subject invention, a "slush" molding process may be utilized. In this process, a mold (not shown) is provided that has an inner mold surface that is sized and shaped to correspond to the size and shape of the pelvis member <NUM>. The mold includes the insert <NUM> that is sized and shaped and positioned to correspond to the size and shape of the buttock cavity <NUM>, the at least one vent port <NUM> and the corresponding openings <NUM>, with a portion of the insert <NUM> therefore in contact with the inner mold surface.

The mold is filled with a polymeric material used to form the skin <NUM>, typically a vinyl polymer. The vinyl polymer is allowed to dwell for a sufficient period of time to cure along the outer mold surfaces to form the skin <NUM>. The at least one opening <NUM> are created in the formed skin <NUM> during this step corresponding to portions of the insert that are in contact with the inner mold surface. The uncured polymeric material is removed, leaving the inner cavity portion <NUM> contained within the formed skin <NUM>.

Next, a second polymeric material is injected within the mold and foamed to fill up the foam-containing cavity portion <NUM> to form the foam core <NUM>. The mold is opened, and the pelvis member <NUM> including the insert <NUM> is removed from the mold. A slit or cut <NUM> (see <FIG>) is introduced through the skin <NUM> and inner foam material <NUM>, preferably between the vent ports <NUM> and openings <NUM>, to access the insert <NUM>, which is then removed through the slit <NUM>. The slit <NUM> is sealed with adhesive or hot iron melt is used to remelt the foam core <NUM> corresponding to the slit <NUM> together after extracting the insert <NUM>. The removed insert <NUM> thus leaves behind an open cavity that defines the buttock cavity <NUM> contained within the pelvis member <NUM> corresponding to the buttock region <NUM>.

The present invention has been described in an illustrative manner. It is to be understood that the terminology, which has been used, is intended to be in the nature of words of description rather than of limitation.

Claim 1:
An anthropomorphic test device (<NUM>) comprising:
a pelvis member (<NUM>) having a foam core (<NUM>), the pelvis member (<NUM>) including:
an abdomen region (<NUM>) defining a first cavity (<NUM>),
a pair of thigh regions (<NUM>, <NUM>) extending from the abdomen region (<NUM>), and
a buttock region (<NUM>) positioned below the abdomen region (<NUM>) and rearward of the pair of thigh regions (<NUM>, <NUM>),
a structural member (<NUM>) positioned within the first cavity (<NUM>),
characterized in that the buttock region (<NUM>) defines a buttock cavity (<NUM>) separate from the first cavity (<NUM>) with the buttock region (<NUM>) also defining at least one vent port (<NUM>),
wherein the buttock cavity (<NUM>) compresses from an open condition to a collapsed condition when the anthropomorphic test device (<NUM>) is placed onto a surface (<NUM>) for approximating a force applied by a body weight of a human.