Coupling design for coupling simulated flesh to a support structure of an anthropomorphic test device

A method for forming an anthropomorphic test device configured for use in crash test simulations, said method comprising:

• forming a hollow member including a simulated flesh having an inner foam core portion with the formed hollow member defining an inner cavity and forming a channel extending partially through said inner foam core portion;
• coupling one or more inserts within the simulated flesh, wherein each of said one or more inserts comprises:
• a flange portion having an outer surface and an opposing inner surface and positioned within the inner foam core portion such that the inner foam core portion covers at least a portion of the outer surface and at least a portion of said opposing inner surface of the flange portion for at least partially encapsulating the flange portion within the inner foam core portion with a portion of said outer surface not covered with said inner foam core portion and open to the channel;
• and
• an elongated portion extending from the flange portion in a direction opposite the outer surface with the elongated portion defining an elongated opening open to said channel, with the elongated portion extending through the simulated flesh;
• introducing a support structure within the inner cavity of the formed hollow member;
• inserting a fastening member within the insert with the fastening member passing through the channel prior to passing through the elongated opening;
• and
• securing each inserted fastening member to the support structure, and
• forming the channel of the simulated flesh to have a width greater than a width of the elongated opening of the insert.

An anthropomorphic test device configured for use in crash test simulations, said anthropomorphic test device comprising:

• a hollow member comprising a simulated flesh having an inner foam core portion and with said hollow member defining an inner cavity, wherein said hollow member comprises a hollow pelvic member including said simulated flesh having an inner foam core portion and with said hollow pelvic member defining an inner cavity, wherein said hollow pelvic member comprises:
• a pelvic region having an inner surface defining an opening, and
• a pair of upper thigh regions extending from said pelvic region, each of said pair of upper thigh regions having an inner surface and an opposing outer surface extending from an edge portion and with said inner surface defining an insertion opening, with said inner cavity defined within said pelvic region and said pair of upper thigh regions between said opening and each of said pair of insertion opening, wherein each of said pair of upper thigh regions including at least one opening extending from said outer surface to said inner surface;
• a support structure received within said inner cavity, wherein said support structure comprises a pelvic support structure received within said inner cavity, said pelvic support structure comprising:
• a central support structure contained within said pelvic region,
• a pair of pelvic bones coupled to said central support structure and contained within said pelvic region, each of said pair of pelvic bones having an exterior surface positioned adjacent to said inner surface of said pelvic region;
• and
• a pair of upper thigh bones coupled to and extending from said central support structure, with one of said pair of upper thigh bones contained within a corresponding respective one of said pair of upper thigh regions,
• wherein said fastening member passes through said flange portion, extends through and along said elongated portion, and is secured to a respective one of said pair of pelvic bones;
• and
• a mounting mechanism coupled to each of said hollow member and said support structure for maintaining the positioning of said simulated flesh relative to said support structure during the crash test simulations, wherein said mounting mechanism comprises:
• one or more inserts each respectively coupled within said simulated flesh, wherein each of said one or more inserts comprises:
• a flange portion positioned within said inner foam core portion;
• an elongated portion extending from said flange portion towards said support structure;
• a fastening member passing through said flange portion, extending through and along said elongated portion, and secured to said support structure;
• and
• at least one additional fastening member, with each of said at least one additional fasteners coupled within a corresponding one of said at least one openings for securing a respective one of said pair of upper thigh regions to a corresponding one of said pair of upper thigh bones,
• wherein said inner surface of said insertion opening of each of said pair of upper thigh members comprises:
• an inner recessed portion extending from said edge portion;
• an inner stepped portion extending from said inner recessed portion in a direction opposite said edge portion, with said inner stepped portion including said one or more openings, and
• a step edge portion extending transverse to each of said inner recessed portion and said inner stepped portion and connecting said inner recessed portion to said inner stepped portion.