Vehicle seat belt assembly

A seat belt for use in a vehicle including one or more seat cushions adapted to receive one or more vehicle occupants and a method for manufacturing the same is disclosed. The seat belt includes webbing, an anchor loop, and a fold. The anchor loop is formed at an end of the webbing affixed to a body of the webbing and adapted to pass through a belt receptacle anchor adapted to be fastened to a chassis of the vehicle. The fold is formed in the webbing adjacent to the anchor loop, such that a width of the webbing at the fold is less than a width of the webbing in other regions of the body.

TECHNICAL FIELD

The present disclosure relates generally to the automotive field. More particularly, the present disclosure relates to a vehicle seat belt assembly. The seat belt assembly finds applicability in both traditional and autonomous vehicles, especially in rear seat implementations.

BACKGROUND

A typical seat belt assembly includes a webbed synthetic fabric belt that is anchored to the vehicle body and frame at each end, a buckle member that includes a tongue and is slidable along a length of the webbed synthetic fabric belt, and a buckle anchored to the vehicle body and frame adjacent to a vehicle seat that mates with the tongue of the buckle member to secure and occupant seated in the vehicle seat. The webbed synthetic fabric belt can form a three-point seat belt that includes a lap belt that extends from a lower anchor point between seat cushions and/or adjacent to a vehicle seat and across the lap of an occupant to the buckle member and buckle. The three-point seat belt also includes a shoulder belt that extends from the buckle member and buckle across the chest and shoulder of the occupant to an upper anchor point adjacent to the vehicle seat for securing the occupant in the vehicle seat.

The lower anchor point can be disposed at a floor of the vehicle, such as next to and below the vehicle seat. The upper anchor point can be disposed above and/or behind the vehicle seat, such as at a cross-beam positioned behind the seat (such as adjacent to a trunk of the vehicle), at the roof of the vehicle, or at a vertical pillar of the vehicle. The seat belt assembly typically includes a retractor mechanism positioned at the upper (or lower) anchor point. The retractor mechanism generally includes a spool that winds the slack of the webbed synthetic fabric belt within the retractor mechanism, as well as arrests spooling out of the webbed synthetic fabric belt in the event of a vehicle impact event. The retractor mechanism may utilize a suitable pretensioner mechanism as well.

Any interruption in or interference with the webbed synthetic fabric belt between the lower anchor point and the upper anchor point/retraction mechanism can artificially reduce the amount of slack in the webbed synthetic fabric belt available. Such reduced amount of slack can prevent the occupant from properly and comfortably pulling the webbed synthetic fabric belt across his or her body and securing the tongue of buckle member into the buckle. Further, during a vehicle impact event, the forces applied to the occupant, and, in particular, the seat belt assembly, will cause a locking mechanism within the retractor mechanism to lock the spool and prevent any spooled slack of the webbed synthetic fabric belt from being released. By preventing the slack from being released, the occupant is secured in position within the vehicle seat.

The above description relating to seat belts for restraining occupants of a vehicle is merely intended to provide a contextual overview of some current issues and is not intended to be exhaustive. Other contextual information may become apparent to those of ordinary skill in the art upon review of the following description of exemplary embodiments.

SUMMARY

In one exemplary embodiment, the present disclosure provides a seat belt assembly for use in a vehicle including one or more seat cushions adapted to receive one or more vehicle occupants. The seat belt assembly includes an anchor and a seat belt. The anchor is adapted to be fastened to a chassis of the vehicle. The anchor includes a belt receptacle. The seat belt comprises webbing, an anchor loop, and a fold. The anchor loop is formed at an end of the webbing affixed to a body of the webbing and passes through the belt receptacle. The fold is formed in the webbing adjacent to the anchor loop, such that a width of the webbing at the fold is less than a width of the webbing in other regions of the body.

In one exemplary embodiment of the seat belt assembly, the fold is oriented orthogonal to the anchor loop. In another exemplary embodiment of the seat belt assembly, the fold includes sides of the webbing disposed adjacent to one another and held together. In a further exemplary embodiment of the seat belt assembly, the fold is a pleat.

In another exemplary embodiment of the seat belt assembly, the fold includes one or more stitches joining portions of the webbing adjacent to the anchor loop. In a still further exemplary embodiment, the seat belt assembly includes a clip positioned over the fold that holds overlapping portions of the webbing together. In a still further exemplary embodiment, the seat belt assembly includes one or more fasteners that hold overlapping portions of the webbing together at the fold.

In a further exemplary embodiment of the seat belt assembly, the fold includes a first side of the webbing, at a position adjacent to the anchor loop, being folded over a second side of the webbing along the width of the webbing, and one or more stitches joining the first side of the webbing to the second side of the webbing adjacent to the anchor loop.

In a still further embodiment of the seat belt assembly, the fold has a thickness that allows the seat belt to pass adjacent to or between the one or more seat cushions when the anchor is fastened to the chassis of the vehicle.

In another exemplary embodiment, the present disclosure provides a seat belt for use in a vehicle including one or more seat cushions adapted to receive one or more vehicle occupants. The seat belt includes webbing, an anchor loop, and a fold. The anchor loop is formed at an end of the webbing affixed to a body of the webbing and adapted to pass through a belt receptacle anchor adapted to be fastened to a chassis of the vehicle. The fold is formed in the webbing adjacent to the anchor loop, such that a width of the webbing at the fold is less than a width of the webbing in other regions of the body.

In one exemplary embodiment of the seat belt, the fold is oriented orthogonal to the anchor loop. In another embodiment of the seat belt, the fold includes sides of the webbing disposed adjacent to one another and held together.

In another exemplary embodiment of the seat belt, the fold includes one or more stitches joining portions of the webbing adjacent to the anchor loop. In a further exemplary embodiment the seat belt includes a clip positioned over the fold that holds overlapping portions of the webbing together. In a still further exemplary embodiment of the seat belt, the seat belt includes one or more fasteners that hold overlapping portions of the webbing together at the fold.

In a further exemplary embodiment of the seat belt, the fold has a thickness that allows the seat belt to pass adjacent to or between the one or more seat cushions when the anchor is fastened to the chassis of the vehicle.

In a further exemplary embodiment, the present disclosure provides a method for producing a seat belt. The method includes providing webbing. The method also includes forming a loop in an end of the webbing. The method further includes forming a fold in the webbing adjacent to the loop formed in the end of the webbing, such that a width of the webbing at the fold is less than a width of the webbing in other regions of the seat belt.

In one exemplary embodiment of the method, the fold is oriented orthogonal to the loop. In another exemplary embodiment of the method, the method includes securing the fold in the webbing using one or more of: one or more stitches disposed through the fold, a fastener disposed through the fold, and a clip disposed over the fold.

In a further exemplary embodiment of the method, forming the loop in the end of the webbing further comprises securing the loop through a belt receptacle anchor adapted to be fastened to a chassis of a vehicle.

DESCRIPTION OF EXEMPLARY EMBODIMENTS

Again, any interruption in or interference with the webbed synthetic fabric belt of a seat belt between the lower anchor point and the upper anchor point/retraction mechanism can artificially reduce the amount of slack in the webbed synthetic fabric belt available. Such reduced amount of slack can prevent the occupant from properly and comfortably pulling the webbed synthetic fabric belt across his or her body and securing the tongue of buckle member into the buckle. Further, during a vehicle impact event, the forces applied to the occupant, and, in particular, the seat belt assembly, will cause a locking mechanism within the retractor mechanism to lock the spool and prevent any spooled slack of the webbed synthetic fabric belt from being released. By preventing the slack from being released, the occupant is secured in position within the vehicle seat. However, the forces of the vehicle impact event may cause any webbed synthetic fabric belt “pinched” between the seat cushions, for example, to be suddenly released therefrom. The release of this trapped material results in an undesirable, sudden lengthening of the webbed synthetic fabric belt as the slack is released. This can allow the occupant to move relative to the vehicle seat due to the excess slack present in the webbed synthetic fabric belt during the vehicle impact event. When this occupant motion relative to the vehicle seat is suddenly arrested by the now-lengthened webbed synthetic fabric belt, occupant seat belt injury can result.

The seat cushions of the vehicle are typically installed in the vehicle after the webbed synthetic fabric belt is secured to the lower and upper anchor points. As can be seen inFIG. 1, which illustrates such an installation, the webbed synthetic fabric belt10can be trapped on a back22of a seat cushion20, especially between adjacent seat cushions20, which causes the webbed fabric synthetic belt10to loop around the back22of the seat cushion20, again, especially between adjacent seat cushions20. Rather than pass next to the seat cushion20, through a slot in the seat cushion20, or between the seat cushion20and an adjacent seat cushion20, the webbed synthetic fabric belt10is caught between the back22of the seat cushion20and the bottom32of the seat back cushion30, for example. The resulting loop in the webbed synthetic fabric belt10thus captures slack that would normally be taken up by the spool when the webbed synthetic fabric belt10properly passes next to the seat cushion20, through a slot in the seat cushion20or between the seat cushion20and an adjacent seat cushion20. It is this captured slack that may be suddenly released during a vehicle impact event, potentially leading to occupant seat belt injury.

Thus, the present disclosure generally provides a seat belt assembly for use in a vehicle. The seat belt assembly includes a seat belt that is secured to the vehicle chassis by an anchor and that secures a vehicle occupant in a seat of the vehicle. The seat belt includes webbing and an anchor loop that secures the webbing to the anchor. The seat belt also includes a fold in the webbing adjacent to the anchor loop, such that a width of the webbing at the fold is less than a width of the webbing in other regions of the webbing. This fold narrows a width in the webbing in a region of the seat belt that is adapted to pass adjacent to a seat cushion, into a slot in the seat cushion, or between adjacent seat cushions during installation of the seat cushion(s). The narrow width of the webbing prevents the webbing from snagging or catching on a back of the seat cushion during installation of the seat cushion and helps assure that the webbing is properly situated relative to the seat cushion(s).

During the vehicle assembly process, the seat cushion(s) of the vehicle can be installed after the seat belt assembly is secured to the vehicle chassis at the anchor points. As the seat cushion(s) are installed, the seat belt passes adjacent to a seat cushion, into a slot of the seat cushion, or between adjacent seat cushions. The narrow width of the seat belt at the fold of the present disclosure allows the seat belt to pass adjacent to a seat cushion, into the slot of the seat belt cushion, or between adjacent seat cushions and reduces the chances that the seat belt can snag or catch on the back of a seat cushion during installation of the seat cushion(s). This helps assure that the seat belt is properly situated relative to the seat cushions(s) after the seat cushion(s) are installed and prevents excess slack from being released and present in the seat belt during a vehicle impact event.

FIG. 2is a side perspective view of one exemplary embodiment of the seat belt assembly100ofFIG. 1and components of the vehicle surrounding the seat belt assembly100.FIG. 3is a front perspective view of the seat belt assembly100at a fold112of the seat belt110of the seat belt assembly100and an anchor130for the seat belt110of the seat belt assembly100ofFIG. 2.

Referring toFIGS. 2 and 3, the seat belt assembly100of the present disclosure is for use in a vehicle that includes one or more seat cushions20adapted to receive one or more occupants of the vehicle. The vehicle also includes back cushions30that correspond to the seat cushions20and provide support for the back of the occupants of the vehicle. The seat cushions20are positioned adjacent to a lower portion50of the chassis, and the back cushions30are positioned adjacent to an upper portion60of the chassis. The lower portion50, for example, is a floor of the chassis that provides a lower anchor point52for the seat belt assembly100. The upper portion60, for example, is a cross-beam of the chassis that provides an upper anchor point62for the seat belt assembly100. Alternatively, the upper portion60is a roof or a vertical pillar of the chassis that provides the upper anchor point62for the seat belt assembly100.

The seat belt assembly100includes a retractor mechanism120, an anchor130, a buckle member140, and a seat belt110. In the exemplary embodiment, the retractor mechanism120is fixed to the upper portion60of the chassis at the upper anchor point62. The retractor mechanism120is positioned behind and above an upper portion of the back cushion30. The retractor mechanism120includes a spool that winds slack of the seat belt within the retractor mechanism120, which releases the slack to allow an occupant of the vehicle to secure the seat belt in place. The retractor mechanism120also includes a locking mechanism that prevents the slack from being fed from the spool during a crash event. As an alternative, the retractor mechanism120could also be positioned in the backrest of a rear seat, for example, especially in a sport utility vehicle (SUV) or the like.

The anchor130is adapted to fasten to the chassis of the vehicle, and in particular, to the lower portion50of the chassis at the lower anchor point52by a fastener134, such as a bolt or a screw. The anchor130defines a belt receptacle132. The belt receptacle132includes a hole through which the seat belt110passes.

The buckle member140secures the seat belt110to a buckle for securing the occupant of the vehicle to the seat.

In embodiments, the seat belt110is a three-point seat belt that forms a lap belt that extends from the anchor130across the lap of the occupant of the vehicle to the buckle member140and forms a shoulder belt that extends from the buckle member140across the chest and shoulder of the occupant of the vehicle to the retractor mechanism120to secure the occupant of the vehicle in the seat during a crash event.

The seat belt110includes webbing111, an anchor loop116, and a fold112. The webbing111typically extends from the anchor130to the retractor mechanism120, with any excess slack of the webbing111being wound on the spool. The webbing111is a webbed fabric, a webbed synthetic fabric, combinations thereof, or any other suitable material for securing a vehicle occupant in the seat.

The anchor loop116is formed at an end of the webbing111. The anchor loop116is affixed to a body113of the webbing111. For example, an end of the webbing111is folded back over the body113of the webbing111in a length direction of the webbing111and affixed thereto. The end of the webbing111is affixed to the body113of the webbing111in such a manner that the opening in the loop formed thereby is oriented in a width direction of the webbing111. The end of the webbing111is affixed to the body113of the webbing via stitching that extends in the width direction of the webbing111. The stitching is one or more rows of stitching, which results in the anchor loop116being stiffer than the body113of the webbing111. The anchor loop116also passes through the belt receptacle132of the anchor130, which secures the seat belt110to the anchor130.

The fold112is formed in the webbing111adjacent to the anchor loop116, such that a width of the webbing111at the fold112is less than a width of the webbing111in other regions of the body113of the webbing111. In embodiments, the fold112includes a portion of the anchor loop116, such as the portion of the anchor loop116that includes the stitching118. The width of the fold112is also less than the standard width of the anchor loop116. However, the portions of the body111and the anchor loop116, such as at the stitching118, adjoining the fold112, while being wider than the fold112, are narrower than other portions of the body111and the anchor loop116as the webbing111and the anchor loop116in those regions transition from the fold112to the other portions of the body111and the anchor loop116.

In embodiments, the fold112is oriented orthogonal to the anchor loop130. For example, a crease in the webbing111is formed in the length direction of the webbing111that is orthogonal to the direction that the opening of the anchor loop116creates, which extends in the width direction of the webbing111.

In embodiments, the fold112also includes sides of the webbing111that are disposed adjacent to one another and held together, and in some embodiments, the fold112is a pleat.

FIG. 4is a side perspective view of the seat belt assembly100ofFIG. 3at the fold112of the seat belt110of the seat belt assembly100and the anchor130of the seat belt assembly100with one or more stiches114securing the fold112in place.FIG. 5is a side perspective view of the seat belt assembly100ofFIG. 3at the fold112of the seat belt110of the seat belt assembly100and the anchor130of the seat belt assembly130with a fastener115securing the fold112in place.FIG. 6is a side perspective view of the seat belt assembly100ofFIG. 3at the fold112of the seat belt110of the seat belt assembly100and the anchor130of the seat belt assembly100with a clip117securing the fold112in place.

Referring toFIG. 4, in some embodiment, the fold112is held in place such that portions of the webbing111are joined together. In some of these embodiments, the portions of the webbing111are held by one or more stitches114. Further, when the fold112includes a first side of the webbing111, at a position adjacent to the anchor loop116, being folded over a second side of the webbing111along the width of the webbing111, the one or more stitches114optionally join the first side of the webbing111to the second side of the webbing111adjacent to the anchor loop116. The portions of the webbing111are joined adjacent to the anchor loop116, and the one or more stitches114are positioned adjacent to the anchor loop116. Optionally, when more than one stitch is used, the stitches114extend vertically in the length direction of the webbing111, along the sides of the webbing111being held adjacent to one another, which is optionally parallel to any crease formed in the webbing111by the fold112. Or, optionally, the stitches114extend horizontally in the width direction of the webbing111, such that the one or more lines of stitches114extends across the portions of the webbing that are held together, which one or more lines is optionally orthogonal to any crease formed in the webbing111by the fold112. Other patterns of stitching are also considered.

Referring toFIG. 5, the seat belt assembly100, optionally, further includes one or more fasteners115that hold overlapping portions of the webbing111together at the fold112. The one or more fasteners115include, for example, one or more bolts that extend through the overlapping portions of the webbing111and corresponding nuts that are secured to the bolts. Like the stitches114, when more than one set of fasteners115are used, the fasteners, optionally, are positioned in the vertical direction along sides of the webbing111, or in the horizontal direction in the width direction of the webbing111. Other patterns of fasteners are also considered.

Referring toFIG. 6, the seat belt assembly100, optionally, further includes one or more clips117. The one or more clips117are positioned over the fold112and hold the overlapping portions of the webbing111together.

FIG. 7is a front perspective view of the seat belt assembly100and the components of the vehicle surrounding the seat belt assembly100ofFIG. 2. Referring toFIG. 7, as will be described in greater detail below, the fold112has a thickness that allows the seat belt110to pass adjacent to one or more seat cushions20, into a slot formed by the one or more seat cushions20, or between the one or more seat cushions20while the anchor130is fastened to the chassis of the vehicle.

FIG. 8is a flowchart of a method700for producing the seat belt110of the seat belt assembly100ofFIGS. 2-6. The method700includes providing webbing111at step702. The webbing111is webbed fabric, webbed synthetic fabric, a combination thereof, and the like.

The method700also includes forming a loop in an end of the webbing111at step704. The loop is the anchor loop116as described in greater detail above.

The method700further includes forming a fold112in the webbing111adjacent to the loop formed in the end of the webbing111, such that a width of the webbing111at the fold112is less than a width of the webbing111in other regions of the seat belt110. In some embodiments of the method, the fold112is oriented orthogonal to the loop.

In embodiments, the loop is formed in the end of the webbing111by folding an end of the webbing111back over a body of the webbing111and stitching the end to the body111of the webbing111. The loop and the stitching result in this region of the seat belt110being stiffer than other portions of the seat belt110. In embodiments, this stiffness facilitates the formation of the fold112in the webbing111.

In embodiments, the method700also includes securing the fold112in the webbing111using one or more of: one or more stitches114disposed through the fold112, a fastener115disposed through the fold112, and a clip117disposed over the fold112. In embodiments, the one or more stiches114, the fastener115, and the clip117are positioned or formed in any of the orientations disclosed above.

In some embodiments of the method700, forming the loop in the end of the webbing111further comprises securing the loop through a belt receptacle132of an anchor130adapted to be fastened to a chassis of a vehicle. The loop is fed through the belt receptacle132before the end of the webbing111is secured to the body113of the webbing111.

In embodiments, the method700also includes forming the fold112, adding stitches114in any other manner as disclosed herein, such as forming the fold112as a pleat, and the like.

Referring again toFIGS. 2 and 7, and as noted above, during the manufacturing process of the vehicle, the seat cushion(s)20of the vehicle are installed after the seat belt assembly110is secured therein, such as after the retractor mechanism120is secured to the upper portion60of the chassis at the upper anchor point62and the anchor130is secured to the lower portion50of the chassis at the lower anchor point50. As the seat cushion(s)20are installed, the webbing111of the seat belt110, and in particular the fold112of the seat belt110passes adjacent to a seat cushion20, into a slot of the seat cushion20, or between adjacent seat cushions20.

The narrower width of the seat belt110at the fold112facilitates the webbing111to pass by end corner(s) of the seat cushion(s)20without snagging or catching thereon during installation of the seat cushion(s)20. This helps assure that the seat belt110is properly situated relative to the seat cushions(s)20after the seat cushion(s)20are installed.

Further, by preventing the webbing111from snagging or catching a corner of a seat cushion20, excess slack is not taken from the spool, which helps assure proper operation of the seat belt assembly100. For example, with the proper amount of slack on the spool an occupant of the vehicle is able to properly pull the seat belt across the occupant's body to secure the buckle member140in the buckle without running out of slack. Further, since there is no excess slack in the seat belt110, in the event of a crash event, such slack cannot be released and the seat belt assembly100will maintain a proper amount of tension in the seat belt110and properly secure the occupant of the vehicle during a crash event.