Seat belt retractor with integrally formed frame

Abstract

A seat belt retractor ( 20 ) characterized by low mass and low operating noise, resistant to dust, moisture, and corrosion comprising: an integrally formed, quadrilaterally shaped main body portion ( 24 ). In the preferred embodiment of the invention the frame is injection molded using 50% or greater long glass fiber plastic or die cast or injection molded metal. A spring housing wall and wall of a mechanism cover are also integrally formed in the sides of the retractor. Positioned within the spring housing wall is a spring coil guide, as well as an integrally formed anchor, which is used to hold the outer end of a rewind spring. The mechanism side of the frame further includes an integrally formed post or pin to pivotally support a locking pawl.

1 . A seat belt retractor ( 20 ) characterized by low operating noise, dust, corrosion and moisture resistance comprising: 
 an integrally formed frame having a quadrilaterally shaped main body ( 24 ) and at least one mounting member ( 60 ).    
     
     
         2 . The retractor as defined in  claim 1  wherein the frame is made from one of a polymer having at least a 50% content of glass fibers.  
     
     
         3 . The retractor as defined in  claim 2  wherein most of the glass fibers are at least 2000 microns in length.  
     
     
         4 . The retractor as defined in  claim 1  wherein the main body ( 24 ) includes integrally formed secondary features including: an integrally formed spring wall ( 140 ) for forming a spring cavity for receipt of a rewind spring ( 130 ).  
     
     
         5 . The retractor as defined in  claim 4  wherein the integrally formed secondary features further include an integrally formed mechanism housing wall ( 170 ).  
     
     
         6 . The retractor as defined in  claim 4  wherein the secondary features include a vehicle sensor support.  
     
     
         7 . The retractor as defined in  claim 4  wherein the secondary features include a pin integrally formed on a side of the frame, the pin adapted to rotationally support a lock pawl.  
     
     
         8 . The retractor as defined in  claim 7  wherein the pin is provided with a means for flexing in response to reaction forces generated through the lock pawl.  
     
     
         9 . The retractor as defined in  claim 8  wherein the frame includes a distributing structure to distribute pin reaction forces without the sides of the frame.  
     
     
         10 . The retractor as defined in  claim 9  wherein the distributing structure includes a strut ( 252 ) that links opposing frame sides and includes extending portions positioned below the lock pawl to receive the lock pawl as the pin deforms.  
     
     
         11 . The retractor as defined in  claim 1  wherein the lower mounting member ( 30 ) includes one of a hook and a cavity adapted to receive a mating member ( 98 ; 100 ) of a mounting surface.  
     
     
         12 . The retractor as defined in  claim 11  further including an upper mounting member adapted to be attached to another portion of the mounting surface.  
     
     
         13 . The retractor as defined in  claim 1  wherein the main body portion includes integrally formed sides and wherein the each side only includes one opening.  
     
     
         14 . The retractor as defined in  claim 13  wherein the main body portion includes integrally formed bearing surfaces on each side.  
     
     
         15 . The retractor as defined in  claim 1  wherein the secondary features are integrally molded into the main body providing improved dimensional control from reduced part count and complexity.  
     
     
         16 . The retractor as defined in  claim 5  including a first and a second mechanism housing wall separated by a space ( 171 ) from the first mechanism housing wall.  
     
     
         17 . The retractor as defined in  claim 16  including acoustic insulation between the first and second mechanism housing walls.  
     
     
         18 . A seat belt retractor ( 20 ) comprising: 
 a composite, reinforced resin frame ( 22 ) with integral provision to accept and receive a spool and a quantity of seat belt webbing, the frame capable of withstanding an empty spool pull test of about at least 1136 Kg).    
     
     
         19 . The retractor as defined in  claim 18  wherein the frame is made from one of a polymer having at least a 50% content of glass fibers.  
     
     
         20 . The retractor as defined in  claim 19  wherein most of the glass fibers are at least 2000 microns in length.  
     
     
         21 . The retractor as defined in  claim 1  further including a lock wheel with a plurality of teeth and a lock pawl with at least two lock teeth adapted to engage corresponding teeth on the lock wheel, and wherein the lock pawl includes first means for enabling the lock pawl to flex under determinable crash loads, wherein in response to such flexing, both teeth of the lock pawl will engage a corresponding tooth of the lock wheel.  
     
     
         22 . A combination of seat belt retractor ( 20 ) and a mounting surface upon which the retractor is mounted, 
 the retractor including: 
 a frame which supports a spool on which a seat belt is wound, the frame includes a lower mounting member ( 60 ) in the form of one of a cavity and a hook and the mounting surface includes a mounting element adapted to be received within the cavity or hook, the lower mounting member, when the retractor is under load, absorbing most of the crash forces, the frame further including an upper mounting member ( 160 ) the purpose of which is to prevent upper portions of the frame from moving away from the mounting surface.  
   
     
     
         23 . A seat belt retractor comprising: 
 a lock wheel having a plurality of teeth and a lock pawl for lockingly engaging the lock wheel, means for moving the lock pawl from a disengaged position into engagement with the teeth of the lock wheel, the lock pawl including at least two lock teeth adapted to engage corresponding teeth on the lock wheel, and wherein the lock pawl includes first means for enabling the lock pawl to flex under determinable crash loads, wherein in response to such flexing, both teeth of the lock pawl will engage a corresponding tooth of the lock wheel.    
     
     
         24 . The retractor as defined in  claim 23  including a frame formed of a resin, reinforced material, the frame including a pin ( 210 ) for rotationally supporting the lock pawl, wherein the pin is provided with a means for permitting the pin to flex in response to reaction forces generated through the lock pawl.  
     
     
         25 . The retractor as defined in  claim 24  wherein the frame includes a distributing structure to distribute pin reaction forces without the sides of the frame.  
     
     
         26 . The retractor as defined in  claim 25  wherein the distributing structure includes a strut ( 252 ) that links opposing frame sides and includes extending portions positioned below the lock pawl to receive the lock pawl as the pin deforms.