Hermetically sealed locking retractor

An apparatus and method are provided for hermetically sealing locking components of a retractor wherein the retractor has a spool shaft extending therefrom. An open-ended housing has a base and defines an opening through the base into an interior of the housing. The base of the housing is mounted to the retractor with the spool shaft accessible via the opening. The locking components are arranged within the housing. A sealing member is positioned about the opening to form a hermetic seal between the spool shaft and the opening. A cover is hermetically attached to the open end of the housing.

FIELD OF THE INVENTION

The present invention relates generally to locking retractors, and more specifically to apparatuses and methods for hermetically sealing locking components of such retractors.

BACKGROUND

Locking retractors are known, and operate to lock under various operating conditions to prevent movement of a web attached thereto. For example, an automatic locking retractor (ALR) may operate to automatically lock after slack in the web is taken up by the retractor following pay out of the web, e.g., after attachment of the web to another structure such as a tongue or buckle. An emergency locking retractor (ELR), on the other hand, may lock only under certain emergency conditions such as during rapid deceleration and/or vehicle impact. Conventional embodiments of such retractors are susceptible to the ingress of moisture and particulate matter into the locking components, which could compromise the locking operation of such locking components. It is therefore desirable to provide a retractor in which the locking components are sealed from moisture and particulate matter ingress.

SUMMARY

The present invention may comprise one or more of the features recited in the attached claims, and/or one or more of the following features and combinations thereof. A method is provided for hermetically sealing locking components of a retractor, wherein the locking components cooperate with a spool shaft extending from a rotatable spool of the retractor to selectively lock rotation of the spool. The method may comprise mounting a base of an open-ended housing to the retractor, wherein the housing may define a first opening through the base into an interior of the housing, and the spool shaft is accessible via the first opening when the base of the housing is mounted to the retractor, positioning a first sealing member about the first opening such that the first sealing member forms a hermetic seal between the spool shaft and the first opening, operatively arranging the locking components within the interior of the housing, and hermetically sealing a cover to the open end of the housing after the housing is mounted to the retractor, the first sealing member is positioned about the first opening and the locking components are operatively arranged within the interior of the housing.

The foregoing method may further include the subject matter of any one and/or any combination of the following 11 paragraphs.

Positioning the first sealing member about the first opening may comprise positioning the first sealing member such that the first sealing member engages the housing about the first opening and also engages the spool shaft circumferentially about the spool shaft when the housing is mounted to the retractor such that the first sealing member forms the hermetic seal between the first opening of the housing and the spool shaft.

The housing may define a channel extending into the base of the housing about the first opening, the channel sized to receive and retain therein the first sealing member, and positioning the first sealing member about the first opening may comprise inserting the first sealing member into the channel.

The retractor may comprise a frame defining a frame sidewall through which the spool shaft extends, and mounting the base of the open-ended housing to the retractor may comprise mounting the base of the open-ended housing to the frame sidewall with an exterior surface of the base opposite to the interior of the housing in contact with the frame sidewall.

The frame sidewall and the base of the open-ended housing may each define at least one mounting aperture therethrough and the cover defines at least one mounting aperture therein, and mounting the base of the open-ended housing to the retractor may comprise passing at least one fixation member through the at least one mounting aperture defined through the frame sidewall and through the at least one mounting aperture defined through the base of the open-ended housing and securing the at least one fixation element within the at least one mounting aperture defined in the cover to thereby secure the housing and the cover, with the locking components operatively arranged within the interior of the housing, to the frame sidewall of the retractor.

Mounting the base of the open-ended housing to the retractor may comprise affixing the exterior surface of the base of the housing to the frame sidewall.

Affixing the exterior surface of the base of the housing to the frame sidewall may comprise interposing a bonding medium between and in contact with the exterior surface of the base of the housing and the frame sidewall.

The retractor may include a locking bar movably mounted to the frame sidewall and engageable with the spool to lock rotation of the spool relative to the frame sidewall, and wherein the locking components control a position of the locking bar to selectively lock the spool relative to the frame sidewall. The housing may define a second opening, separate from the first opening, through the base, and one end of the locking bar may be accessible via the second opening when the base of the housing is mounted to the retractor. The method may further comprise positioning a second sealing member about the second opening, and mounting one of the locking components to the one end of the locking bar such that the second sealing member forms a hermetic seal between the one of the locking components and the second opening. Hermetically sealing a cover to the open end of the housing may comprise hermetically sealing the cover to the open end of the housing after the housing is mounted to the retractor, the first sealing member is positioned about the first opening, the second sealing member is positioned about the second opening, the one of the locking components is mounted to the one end of the locking bar through the second opening and remaining ones of the locking components are operatively arranged within the interior of the housing.

Positioning the second sealing member about the second opening may comprise positioning the second sealing member such that the second sealing member engages the housing about the second opening and also engages the one of the locking components when the one of the locking components is mounted to the one end of the locking bar through the second opening such that the second sealing member forms the hermetic seal between the second opening of the housing and the one of the locking components.

The housing may define a channel extending into the base of the housing about the second opening, the channel sized to receive and retain therein the second sealing member, and positioning the second sealing member about the second opening may comprise inserting the second sealing member into the channel.

The open-ended housing may comprise a housing sidewall extending from the base about an outer perimeter of the housing such that the interior of the housing is defined between the base of the housing and the housing sidewall, a free end of the housing sidewall defining one of a channel and a lip. The cover may comprise a cover sidewall extending about an outer perimeter thereof, a free end of the cover sidewall defining the other of a channel and a lip configured complementarily to the one of the channel and the lip defined by the housing sidewall. Hermetically sealing the cover to the open end of the housing may comprise bringing the one of the channel and the lip of the housing sidewall into contact with the other of the channel and the lip of the cover, and hermetically sealing the free end of the cover sidewall to the free end of the housing sidewall such that the lip forms a hermetic seal with the channel.

Hermetically sealing the free end of the cover sidewall to the free end of the housing sidewall may comprise ultrasonically welding the free end of the cover sidewall to the free end of the housing sidewall.

An apparatus is provided for hermetically sealing locking components of a retractor, wherein the locking components cooperate with a spool shaft extending from a rotatable spool of the retractor to selectively lock rotation of the spool. The apparatus may comprise an open-ended housing having a base defining a first opening therethrough into an interior of the housing, the base of the housing mounted to the retractor with the spool shaft accessible via the first opening, the locking components arranged within the interior of the housing, a first sealing member positioned about the first opening to form a hermetic seal between the spool shaft and the first opening, and a cover hermetically attached to the open end of the housing.

The foregoing apparatus may further include the subject matter of any one and/or any combination of the following 8 paragraphs.

The housing and the cover may each be formed of a polymer.

The locking components may be configured to cooperate with the spool to form at least one of an emergency locking retractor and an automatic locking retractor.

The housing may define a first channel extending into the base of the housing about the first opening, the first channel sized to receive and retain therein the first sealing member. The first sealing member may be positioned within the first channel such that the first sealing member engages the housing about the first opening and also engages the spool shaft about the spool shaft when the housing is mounted to the retractor, the first sealing member thereby forming the hermetic seal between the first opening of the housing and the spool shaft.

The first channel may extend into one of an inner surface and an outer surface of the base of the housing about the first opening.

The retractor may further include a frame sidewall through which the spool shaft extends and to which the base of the housing is mounted, and a locking bar movably mounted to the frame sidewall and engageable with the spool to lock rotation of the spool relative to the frame sidewall, and the locking components may control a position of the locking bar to selectively lock the spool relative to the frame sidewall. The base of the housing may further define a second opening therethrough, separate from the first opening, such that one end of the locking bar is accessible through the second opening when the base of the housing is mounted to the frame sidewall, and one of the locking components may be mounted to the one end of the locking bar, and wherein the apparatus further comprises a second sealing member positioned about the second opening such that the second sealing member forms a hermetic seal between the one of the locking components and the second opening.

The housing may define a second channel extending into the base of the housing about the second opening, the second channel sized to receive and retain therein the second sealing member, and the second sealing member may be positioned within the second channel such that the second sealing member engages the housing about the second opening and also engages the one of the locking components mounted to the one end of the locking bar when the housing is mounted to the retractor, the second sealing member thereby forming the hermetic seal between the second opening of the housing and the one of the locking components.

The second channel may extend into one of an inner surface and an outer surface of the base of the housing about the second opening.

The locking components may be configured to cooperate with the spool and with the locking bar to form at least one of an emergency locking retractor and an automatic locking retractor.

A locking retractor may comprise a frame defining two opposing sidewalls, a spool extending between the two sidewalls and rotatable about a spool shaft relative to the frame, one end of the spool shaft extending through one of the sidewalls, an open-ended housing having a base defining a first opening therethrough into an interior of the housing, the base of the housing mounted to the one of the sidewalls with the spool shaft accessible via the first opening of the open-ended housing, one or more locking components arranged within the interior of the housing, the one or more locking components configured to cooperate with the spool shaft to selectively lock rotation of the spool relative to the frame, a sealing member positioned about the first opening to form a hermetic seal between the spool shaft and the first opening, and a cover hermetically attached to the open end of the housing with the one or more locking components contained within the interior of the housing.

The foregoing retractor may further include the subject matter of any one and/or any combination of the following 4 paragraphs.

The one or more locking components may be configured to cooperate with the spool shaft to form at least one of an emergency locking retractor and an automatic locking retractor.

The retractor may further comprise at least one ratchet wheel mounted to and rotatable with the spool, a locking bar mounted between the two opposing sidewalls of the frame, the locking bar movable relative to the frame between a first position in which the locking bar engages the at least one ratchet wheel and a second position in which the locking bar does not engage the at least one ratchet wheel, one end of the locking bar extending through the one of the sidewalls, wherein the base of the open-ended housing defines a second opening therethrough separate from the first opening, and the one end of the locking bar is accessible via the second opening, and wherein one of the one or more locking components is mounted to the one end of the locking bar, and a second sealing member positioned about the second opening such that the second sealing member forms a hermetic seal between the one of the one or more locking components and the second opening, wherein the one or more locking components control the locking bar between the first and second positions thereof to selectively lock the spool relative to the frame sidewall.

The locking components may be configured to cooperate with the spool and with the locking bar to form at least one of an emergency locking retractor and an automatic locking retractor.

The housing and the cover may each be formed of a polymer.

DESCRIPTION OF THE ILLUSTRATIVE EMBODIMENTS

For the purposes of promoting an understanding of the principles of the invention, reference will now be made to a number of illustrative embodiments shown in the attached drawings and specific language will be used to describe the same.

Referring now toFIG. 1, an apparatus10is illustrated for hermetically sealing locking components12of a retractor14to produce a hermetically sealed locking retractor5. The locking components12may include one or more locking components, and the locking components12make up a spool locking apparatus or assembly. As used herein, the terms “locking components, “spool locking apparatus” and “spool locking assembly” may be used interchangeably and each such term refers to the one or more locking components12which operate to lock rotation of the spool20under certain operating conditions of the retractor5. In one embodiment, for example, as will be shown and described in detail hereinafter, the spool locking apparatus12illustratively includes one or more locking components that lock rotation of the spool20under one or more “emergency conditions” such that the resulting hermetically sealed locking retractor5is, in such embodiments, a so-called conventional emergency locking retractor or ELR. In other embodiments, the spool locking apparatus12illustratively includes one or more locking components that automatically lock rotation of the spool20under one or more “non-emergency conditions” such that the resulting hermetically sealed locking retractor5is, in such embodiments, a so-called automatic locking retractor or ALR. In still other embodiments, the spool locking apparatus12illustratively includes one or more locking components that automatically lock rotation of the spool20under one or more non-emergency conditions and one or more locking components that lock rotation of the spool20under one or more emergency conditions such that the resulting hermetically sealed locking retractor5is, in such embodiments, a combination ALR and ELR.

The “emergency conditions” under which the one or more locking components lock rotation of the spool20may include, but are not limited to, one or more of (1) one or more orientations of the retractor5relative to the direction of gravity, i.e., relative to earth, (2) when the rotational speed of the spool20exceeds a threshold speed, i.e., inertial locking, and (3) when the retractor5decelerates at a rate that is greater than a deceleration threshold, e.g., during a vehicle crash. The “non-emergency conditions” under which the one or more locking components lock rotation of the spool20may include, but are not limited to, automatically locking the spool at a set position of the spool20, e.g., after the spool20has traveled a distance in the web payout direction that corresponds to, for example, extension of a predetermined length of web from the retractor. In some embodiments, the spool20may thereafter rotate in the web take-up direction to a desired position, e.g., to a desired position of the web, such that the spool20locks at that desired position and thereafter cannot rotate in the web payout direction.

For clarity of illustration, the spool locking apparatus12is illustrated inFIG. 1as a single generic structure, although it will be understood that depending upon the configuration of the spool locking apparatus12, i.e., as between an ELR, an ALR or both, the spool locking apparatus12may be implemented an assembly that includes a plurality of locking components. Alternatively or additionally, depending upon the configuration of the retractor14with which the spool locking apparatus12interfaces, the spool locking apparatus12may be configured to operatively engage one or multiple components of the retractor14.

In the embodiment illustrated inFIG. 1, the retractor14includes a frame18having a pair of sidewalls18A and18B that extend away from a base18C of the frame18. Illustratively, the sidewalls18A and18B are substantially parallel. In any case, a space is defined between the sidewalls18A and18B and a spool20is rotatably mounted between the sidewalls18A and18B in a conventional manner. One end of a conventional flexible web (not shown) will typically be attached to the spool20, and such a web will be wrapped around the spool20in a conventional manner. A free end (not shown) of the web will generally extend from the retractor14, and an engagement member (not shown), e.g., a hook or other conventional engagement member, may be attached to the free end of the web. A conventional power spring assembly22, e.g., a power spring contained within a housing or cover, is attached between the spool20and the sidewall18A of the frame18. The power spring is configured in a conventional manner to apply a rotational biasing force to the spool20in a web take up direction, which rotational biasing force may be manually overcome when the retractor14is not locked by the locking components12from rotating the spool20in an opposite web payout direction to draw web from the spool20. The hermetically sealing apparatus10including the spool locking apparatus12contained therein is illustratively mounted to the opposite sidewall18B, and the spool locking apparatus12is therefore illustratively hermetically sealed by the apparatus10as will be described in greater detail hereinafter. Hermetic sealing of the locking components12by the apparatus10blocks ingress of moisture and particles to the locking components12such that the locking components12are maintained functional during exposure of the retractor5to harsh environments such as, for example, dust, dirt and mud, and including full or partial immersion of the retractor5in water that may include various amounts of dirt or mud, e.g., ponds, lakes, streams, ditches, puddles, etc.

A spool shaft30is rigidly mounted to the spool20such that the shaft30rotates with the spool20. The spool shaft30extends through the sidewall18B of the frame18and extends outwardly away from the sidewall18B as shown inFIG. 1. In the embodiment of the retractor14illustrated inFIG. 1, a conventional locking bar32is movably mounted to and between the sidewalls18A and18B, and one end32A of the locking bar32extends through an opening18D in the sidewall18B and at least partially extends outwardly away from the sidewall18B. The locking bar32is conventional and is normally biased, e.g., via a spring (not shown) attached between the locking bar32and the frame18, away from the spool20so that the spool20may rotate in either of the web take up or web pay out directions. When the retractor14is locked, e.g., via the locking components12, the locking bar32is forced toward the spool20and engages teeth (not shown) formed on at least one ratchet wheel mounted to the spool20. In the illustrated embodiment, two such ratchet wheels34A and34B are mounted to the spool20at opposite ends thereof. In the illustrated embodiment, the locking bar32engages the teeth of the ratchet wheels34A and34B when the retractor14is locked, thereby preventing rotational movement of the spool20in the web payout direction in a conventional manner.

In the embodiment illustrated inFIG. 1, the apparatus10for hermetically sealing locking components12of the retractor5includes a housing40, housing cover42and two sealing members44and46. Referring now toFIGS. 1 and 2, the housing40is illustratively an open-ended housing having a base40M defining an inner surface40A and an outer surface40B opposite the inner surface40A. A housing sidewall40C extends outwardly away from the inner surface40A of the base40M about an outer periphery of the housing40. The base40M of the housing40defines two separate openings40D and40E respectively therethrough, and a pocket40H sized to receive a locking actuator component of the spool locking apparatus12as will be illustrated and described hereinafter. The opening40D is sized to receive therethrough the spool shaft30and the second opening40E is sized to provide access to the end32A of the locking bar32when the outer surface40B of the base40M of the housing40is mounted to the sidewall18B of the frame18. The housing40is configured such that the openings40D and40E align with the spool shaft30and the end32A of the locking bar32respectively when the base40M of the housing40is mounted to the sidewall18B.

As illustrated by example inFIGS. 1 and 2, the sidewall18B of the frame18and/or the base40M of the housing40may be configured to accommodate mounting to the other. Such configuration may, for example, facilitate alignment of the housing40relative to the sidewall18B, facilitate mounting of the housing40to the sidewall18B and/or accommodate one or more features of the housing40and/or sidewall18B. For example, the pocket40H formed in the base40M and extending into the inner surface40A produces a protrusion40H from the outer surface40B, and a window18E is therefore formed through the sidewall18B of the frame18which is sized to receive the pocket40H therein. A fastening site40J is also illustratively formed on the pocket40H on the outer surface40B of the housing40, and the fastening site40J is sized to receive therein a fixation member such that an optional cover (not shown) may be placed over the window18E on the inside surface of the sidewall18B and fixed in place via such a fixation member.

The housing40may further include a plate40I which extends from the outer surface40B of the base40M of the hosing40, which plate40I may extend under an indented portion18J of the frame18between the sidewall18B and the base18C. The housing40may further include protrusions43A and43B which extend outwardly from the outer or bottom surface40B of the housing40, and the sidewall18B may define a corresponding pair of openings18H and18I therethrough which are sized to receive therein the protrusions43A and43B respectively. Alternatively, either or both of the protrusions may be formed on the sidewall18B and either or both corresponding openings may be formed into, but not through, the outer surface40B of the housing40.

Generally, the base40M of the housing40is mounted to the retractor14, and more specifically the base40M of the housing40is illustratively mounted to the sidewall18B of the frame18with the outer surface40B of the base40M in contact with the outer face of the sidewall18B. In the embodiment shown inFIGS. 1 and 2, this mounting is illustratively accomplished by passing one or more fixation members through the sidewall18B, through openings defined through the housing40and into engagement with the cover42. In the illustrated example, two openings18F and18G are defined through the sidewall18B of the frame18, and corresponding openings41A and41B are defined through the base40M of the housing. As illustrated inFIGS. 1,4A-4B,7,9and10, however, the openings41A and41B are formed outside of the interior of the open-ended housing, which interior is defined and bounded by the inner surface40A of the base40A and a continuous inner surface of the sidewall40C which extends about the periphery of the housing40. Then openings41A and41B defined through the housing40therefore do not extend through the base40M into the interior of the housing40, but rather extend through the base40M of the housing40outside of the interior of the housing40.

In any case, the inside surface of the cover42defines two fastening sites (or mounting apertures)42C and42D as illustrated by example inFIG. 11. Each of the sites42C and42D is configured to receive and engage a corresponding one of two fixation members25A and25B. When the housing40is mounted to the retractor14with the outer surface40B of the base40M in contact with the outer surface of the frame sidewall18B as illustrated inFIG. 1, the openings41A and41B align with the openings18F and18G respectively, and the fixation members25A and25B extend through the aligned opening pairs18F,41A and18G,41B respectively (as clearly illustrated inFIG. 10). After the locking components of the spool locking apparatus12are operatively arranged within the interior of the housing40, the cover42is placed over the open end of the housing40such that the fastening sites42C and42D align with the openings41A and41B (and with the fixation members25A and25B) respectively. The fixation members25A and25B are then manipulated to engage the fastening sites42C and42D respectively to thereby mount the combination of the housing40and the cover42, with the spool locking apparatus12contained therebetween, to the retractor14, i.e., to the frame sidewall18B. Illustratively, the housing40and the cover42are formed by a moldable synthetic or semi-synthetic organic solid material such as a polymer or similar material, although this disclosure contemplates that the housing40and/or cover42may be alternatively formed of one or more additional or other materials.

It will be understood that this disclosure contemplates mounting of the housing40to the frame18of the retractor14using one or more additional or alternative, conventional techniques. As one alternative, or in addition, to the mounting of the housing40to the frame sidewall18B as just described, a bonding medium27may be interposed between and in contact with the outer surface40B of the housing40and the outer surface of the frame sidewall18B as illustrated by dashed-line representation inFIG. 1. The bonding medium27may be any conventional medium which creates a bond between the base40M of the housing40and the frame sidewall18B, examples of which include, but should not be limited to, adhesives, resins, and the like. As another alternative, or in addition, to the mounting of the housing40to the frame sidewall18B as just described and/or to use of a bonding medium27, the housing40may be mounted to the frame sidewall18B using a conventional staking process. In such a process, the protrusions43A and/or43B, and/or one or more additional or alternate protrusions formed on or attached to the outer surface40B of the housing40may be sized and/or configured to be staked to corresponding openings, e.g., openings18H and/or18I and/or one or more additional or alternate openings formed in the frame sidewall18B, to thereby secure the housing40to the frame sidewall18B. One or more conventional mounting structures and/or processes may additionally or alternatively be used to mount the housing40to the frame18of the retractor14, and any such structures and/or processes are contemplated by this disclosure.

Referring still toFIGS. 1 and 2, the sealing member46is positioned about the opening40D defined through the base40M of the housing40. The sealing member46is illustratively configured to extend about and engage the periphery of the opening40D and to extend about and engage the periphery of the spool shaft30when the base40M of the housing40is mounted to the sidewall18B of the frame18such that a hermetic seal is formed between the housing40and the spool shaft30. In one embodiment, the sealing member46is illustratively a conventional, flexible, e.g., rubber, polymer or the like, annular member. Referring toFIGS. 3A and 3B, plan and cross-sectional views respectively are shown of one illustrative embodiment of the sealing member46. In the illustrated embodiment, the sealing member46is a double ring structure with an outer annular ring46A coupled to an inner ring46D. One end46B of the outer annular ring46A is coextensive with one end46E of the inner annular ring46D such that the ends46B and46E form a continuous, common, flat surface. The opposite end46C of the outer annular ring46A extends beyond the opposite end46F of the inner annular ring46D to provide an offset between the flat ends46C and46F of the annular rings46A and46D respectively. In alternative embodiments, the sealing member46may be a single annular sealing member, or a conventional quad ring, which may be flexible or semi-flexible, although this disclosure contemplates alternative embodiments in which the sealing member46is non-annular, non-flexible and/or is formed of one or more additional or alternative materials.

Referring specifically toFIG. 2, the opening40D formed through the base40M of the housing40includes a channel40F defined and extending into the outer surface40B of the base40M of the housing40, and formed about the periphery of the opening40D. The channel40F is illustratively sized to receive and retain therein the sealing member46. In alternative embodiments, the channel40F may be defined in the inner surface40A surface of the base40M of the housing40about the periphery of the opening40D, or may be formed into the periphery of the opening40D. In any case, the sealing member46is illustratively inserted into the channel40F with the common, flat ends46B and46E in contact with the bottom of the channel40F and with the offset ends46C and46F facing outwardly away from the channel40F.

Referring now toFIGS. 1,2,4A and4B, the sealing member44is positioned about the opening40E defined through the base40M of the housing40. The sealing member44is illustratively configured to extend about and engage the periphery of the opening40E and to extend about, but not engage, the periphery of the end32A of the locking bar32when the housing40is mounted to the sidewall18B of the frame18. In one embodiment, the sealing member44is illustratively a conventional, flexible, e.g., rubber, polymer or the like, annular member substantially identical in structure to, but sized differently than, the sealing member46. Alternatively, the sealing member44may be a single annular sealing member, or a conventional quad ring, and may be flexible or semi-flexible, although this disclosure contemplates alternative embodiments in which the sealing member44is non-annular, non-flexible and/or is formed of one or more additional or alternative materials. In the illustrated embodiment, the opening40E includes a channel40G defined in the inner surface40A of the base40M of the housing40and formed about the periphery of the opening40E. The channel40G is illustratively sized to receive and retain therein the sealing member44. In alternative embodiments, the channel40G may be defined in the outer surface40B surface of the base40M of the housing40about the periphery of the opening40E, or may be formed into the periphery of the opening40E. In any case, the opening40E through the base40M of the housing40is aligned with and extends about the end32A of the locking bar32when the base40D of the housing40is mounted to the frame sidewall18B as illustrated inFIG. 4A. As illustrated inFIG. 4B, the sealing member44is illustratively inserted into the channel40G with the offset end of the outer ring in contact with the bottom of the channel40G (as shown inFIG. 2) and with the common, flat ends of the inner and outer annular rings facing outwardly away from the channel40G (as shown inFIGS. 1,4A and4B).

With the base40M of the housing40mounted to the frame sidewall18Bb as shown inFIGS. 1,4A and4B, the spool shaft30illustratively extends through the opening40D defined through the base40M of the housing40and into the interior of the housing defined and bounded by the inner surface40A of the base40M and the inner surface of the sidewall40C of the housing40. In alternative embodiments, the spool shaft30may not extend completely through the opening40D into the interior of the housing40but may instead terminate at or below the point at which the opening40D opens into the inner surface40A of the base40M of the housing40. For purposes of this disclosure, the phrase “accessible via” used in relation to the spool shaft30and the opening40D formed through the base40M of the housing40should be interpreted to encompass all such embodiments. In particular, the phrase “the spool shaft accessible via the first opening” should be interpreted to mean (1) that the spool shaft30extends into the interior of the housing40defined and bounded by the inner surface40A of the base40M and the inner surface of the sidewall40C surrounding the housing40, (2) that the spool shaft30terminates at the point at which the opening40D opens into the inner surface40A of the base40M of the housing40, or (3) that the spool shaft30terminates below the point at which the opening40D opens into the inner surface40A of the base40M of the housing40.

With the base40M of the housing40mounted to the frame sidewall18Bb as shown inFIGS. 1,4A and4B, the end32A of the locking bar32illustratively extends into the opening40E defined through the base40M of the housing40, but does not clear the top of the channel40G. In alternative embodiments, the end32A of the locking bar32may not terminate at or below the top of the channel40G but may instead extend beyond the top of the channel40G into the interior of the housing40defined and bounded by the inner surface40A of the base40M and the inner surface of the sidewall40C surrounding the housing40. For purposes of this disclosure, the phrase “accessible via” used in relation to the end32A of the locking bar32and the opening40E formed through the base40M of the housing40should be interpreted to encompass all such embodiments. In particular, the phrase “one end of the locking bar accessible via the second opening” should be interpreted to mean (1) that the end32A if the locking bar32A extends into the interior of the housing40defined and bounded by the inner surface40A of the base40M and the inner surface of the sidewall40C surrounding the housing40, (2) that the end32A of the locking bar32terminates at the point at which the opening40E opens into the inner surface40A of the base40M of the housing40, or (3) that the end32A of the locking bar32terminates below the point at which the opening40E opens into the inner surface40A of the base40M of the housing40.

Referring now toFIG. 5, an exploded view is shown of one illustrative embodiment of the spool locking apparatus12illustrating various locking components associated therewith. In the illustrated embodiment, the various locking components include a locking bar engagement member48, a locking plate50, a clutch wheel52, a locking actuator54and a locking plate biasing member56. Starting with the partially constructed locking retractor illustrated inFIG. 4B, construction of the spool locking apparatus12relative to the retractor14illustrated inFIG. 1using the various locking components illustrated inFIG. 5will now be described with reference toFIGS. 6-10.

Referring now toFIG. 6, the locking bar engagement member48ofFIG. 5is shown. The locking bar engagement member48illustratively includes a base48A from which a slotted protrusion48E extends. Illustratively, the base48A is generally formed in the shape of a truncated disc defining a recessed edge48B between truncated ends48C and48D of the base48A, and a lobe or arm48G extends from the base48A opposite the recessed edge48B. The base48A defines an annular channel48F therein about an outer annular surface of the slotted protrusion48E. The channel48F is sized to receive therein in sealing engagement the sealing ring44illustrated inFIGS. 1,2and4B. A slot defined in the slotted protrusion48E is sized and configured to receive therein the end32A of the locking bar32when the base48A of the locking bar engagement member48is mounted within the housing40by forcing the slotted protrusion48E into the space of the opening40E defined by the inner surface of the sealing ring44(as shown inFIG. 4B) with the arm or lobe48G oriented toward the spool shaft30as illustrated by example inFIG. 7. Thus positioned, the sealing ring44forms a hermetic seal between the housing40and the locking bar engagement member48, i.e., between the channel40G defined about the opening40E in the base40M of the housing40and the channel48F defined about the slotted protrusion48E in the base48A of the locking bar engagement member48, while also allowing the locking bar engagement member48to rotate relative to the base40M of the housing about the outer surface of the slotted protrusion48E. The lobe or arm48G is configured to engage a movable post such that movement of the post causes the locking bar engagement member48to rotate relative to the housing40and thereby move the locking bar32into and out of engagement with the teeth of the ratchet wheels34A and34B attached to the spool20of the retractor14as described hereinabove.

Referring now toFIGS. 5 and 8, one illustrative embodiment of the locking plate50is shown. The locking plate50illustratively defines a top surface50A (shown inFIG. 5) and an opposite bottom surface or underside50B (shown inFIG. 8), and an opening50E therethrough that is sized to be received over the spool shaft30onto the base40M of the housing40. The locking plate50is configured to be movably mounted to the base40M of the housing40such that the locking plate50is generally movable about the spool shaft30. Referring toFIG. 8, for example, the underside50B of the locking plate50defines therein an annular channel50C having a channel opening50D. The biasing member56shown inFIG. 5is illustratively a spring in the form of a single wire having one end56A that is received through an opening (not shown) defined in the underside50B of the locking plate50. The body of the wire56is forced into the channel50C formed in the underside50B of the locking plate50, and the hooked opposite end56B of the wire56extends out of the end50D of the channel56as illustrated inFIG. 8. The underside50B of the locking plate50also defines a post50F that engages and moves the lobe or arm48G of the locking bar engagement member48when the locking plate50moves about the spool shaft30as will be described in greater detail hereinafter.

Referring now toFIG. 9, the locking plate50is shown mounted within the housing50with the opening50E engaging ridges defined in the inner surface40A of the housing40and with the hooked end56B of the biasing wire56engaging, e.g., looped around, a protrusion40L extending upwardly away from the inner surface40A of the housing40. The biasing member56normally biases the locking plate in the position illustrated inFIG. 9, and in this position the locking plate engagement member48is in the position illustrated inFIGS. 7 and 9. In this position, hereinafter referred to as the unlocked position of the locking bar32in which the locking bar32does not engage the ratchet wheels34A and34B of the spool20and in which the locking bar32therefore does not lock rotation of the spool20, the post50F defined on the underside50B of the locking plate50does not exert force on the lobe or arm48G of the locking bar engagement member48and the normal bias applied to the locking bar32(discussed hereinabove) therefore maintains the locking bar in the unlocked position. In this position, web can therefore be paid out from the spool20.

During locking conditions of the retractor14, i.e., when the actuator54has been actuated as will be described hereinafter, force applied to the spool20in the web payout direction of the spool20rotates the locking plate50counterclockwise about the spool shaft30against the bias of the biasing member56, as will be described in greater detail hereinafter. This counterclockwise movement of the locking plate50causes the post50F of the movable plate50to force the lobe or arm48G of the locking bar engagement member48downward relative to the housing40toward the protrusion40L such that the locking bar engagement member48moves the locking bar32to a locked position in which the locking bar32engages the ratchet wheels34A and34B of the spool20, thereby locking the spool20from further rotation in the web payout direction.

Referring again toFIGS. 5 and 9, the top surface50A of the locking plate50illustratively defines an annular toothed ring50G about the opening50E with an annular well defined between the toothed ring50G and the opening50E. This annular well is sized to receive therein the clutch52illustrated inFIG. 5. A pawl50H is mounted to the top surface50A of the locking plate50, and is normally biased away from the toothed ring50G.

Referring now toFIG. 10, the clutch52ofFIG. 5has been mounted to the locking plate50and to the spool shaft30through the slot in the clutch52illustrated inFIGS. 5 and 10. The clutch52is illustratively an annular member having a number of teeth formed about its outer periphery. The clutch52rotates with the spool shaft30relative to the locking plate50which generally remains stationary when the retractor14is not locked.

InFIG. 10, the locking actuator54has also been installed in the pocket40H formed into the inner surface40A of the base40M of the housing40. The locking actuator54illustratively includes a ball60and an actuating arm62which contacts the pawl50H under locking conditions. During non-locking conditions of the retractor14, the pawl50H is biased away from the teeth of the clutch52as described above, and the biased pawl50H in turn biases the actuating arm62toward the locking actuator54. During such non-locking conditions, the spool20may rotate in the web payout direction such that web may be paid out therefrom. During certain locking conditions of the retractor14, e.g., gravity-based and inertial-based locking conditions, the ball60moves against and forces the actuating arm62against the pawl50H, which moves the pawl50H into contact with the teeth of the clutch52. Rotation of the spool shaft30in the web payout direction under such conditions brings one of the teeth of the clutch52into contact with the pawl50H, thereby blocking further rotation of the clutch52and locking the clutch52to the locking plate50. Further rotation of the spool shaft30in the web payout direction applies a rotational force to the combination of the clutch52and the locking plate50in the counterclockwise direction against the biasing member56. When this rotational force is greater than the biasing force of the biasing member56, the resulting rotational movement of the combination of the clutch52and the locking plate50in the counterclockwise direction causes the post50F on the underside of the locking plate50to act against and move the lobe or arm48G of the locking bar engagement member48downwardly toward the protrusion40L of the housing40. This movement of the locking bar engagement member48, in turn, causes the locking bar32to move into engagement with the ratchet wheels34A and34B of the spool20to thereby lock the spool20in the web payout direction.

Referring now toFIG. 11, a plan view is shown of the inner surface42A of one illustrative embodiment of the cover42illustrated inFIG. 1. Illustratively, the inner surface42A defines a protrusion42E which, when the cover42is mounted and sealed to the open end of the housing40, extends over the locking bar engagement member48and acts to maintain the locking bar engagement member48in place in the event the locking bar engagement member48moves axially relative to the opening40E through the housing40. The inner surface42A also defines a protrusion42G with an opening sized to receive therein the protrusion40L of the housing40when the cover42is mounted and sealed to the open end of the housing40. The protrusion42G maintains the looped end56B of the wire56on the protrusion40L after the cover42is mounted to the housing40. The inner surface42A also defines another protrusion42H and a lip421that extends radially about the inner surface between the protrusions42G and42H. The protrusion42H and the lip421both extend over the locking plate50and act to maintain the locking plate50in place in the event the locking plate50moves axially relative to the spool shaft30within the housing40. The inner surface42A further defines a pair of protrusions42J and42K which extend over opposite ends of the locking actuator54and act to maintain the locking actuator in place within the pocket40H of the housing40.

Referring now toFIGS. 10 and 11, the free end of the sidewall40C of the housing40illustratively defines a channel or groove40K therein, and the free end of the cover42defines a complementarily configured lip42F. The lip42F is received within the channel40K when the cover42is mounted to the open end of the housing40. Alternatively, the free end of the sidewall40C of the housing may define the lip and the free end of the cover42may define the channel. In any case, the channel40K and the lip42F cooperate to form a hermetic seal between the open end of the housing40and the cover42. In one embodiment, for example, a conventional ultrasonic welding process may be employed to cause the lip42F to melt into the channel40K, thereby hermetically sealing the cover42to the open end of the housing40. Alternatively, a bonding medium, e.g., adhesive, may be interposed between and in contact with the lip42F and the channel40K, or between and in contact with opposing free ends of the cover42and the housing40in embodiments which do not include the channel40K and the lip42F, to thereby bond and hermetically seal the cover42to the open end of the housing40. Those skilled in the art will recognize other conventional processes and structures for forming a hermetic seal between the open end of the housing40and the cover42, and any such other conventional process and/or structure is contemplated by this disclosure. Referring toFIG. 12, the resulting retractor5with hermetically sealed locking components is shown with the cover42hermetically sealed to the open end of the housing40, i.e., attached to the end of the sidewall40C of the housing40.

The concepts of this disclosure may alternatively be used with locking retractors of the ELR and/or ALR variety in which the locking components alone operate to lock the spool shaft30from rotating in the web payout direction during locking conditions. Referring toFIG. 13, such an alternate embodiment is shown in which the retractor14′ does not include a locking bar32as illustrated inFIG. 1. In this embodiment, the housing40′ is modified to omit the opening40E illustrated inFIG. 1, and the sealing member44is likewise omitted. The base40′M of the housing40′ therefore defines only a single opening40′D therethrough, and a single sealing member46is configured to extend about and engage the periphery of the opening40′D such that the sealing member46extends about and engages the periphery of the spool shaft30when the base40′M of the housing40′ is mounted to the sidewall18′B of the frame18′. A hermetic seal is thereby formed between the housing40′ and the spool shaft30, and the cover42is hermetically sealed to the open end of the housing40′ as described above such that the housing40′ is hermetically sealed from external contamination. In operation, the locking components12′ operate in a conventional manner to lock and unlock rotation of the spool20in the web payout direction without the aid of a locking bar of the type illustrated inFIG. 1. As an alternative to the embodiment illustrated inFIG. 13, the retractor14′ need not omit the locking bar32. Thus, the locking bar32may be included as illustrated inFIG. 1, but the spool locking apparatus12′ will not engage or otherwise interface with the locking bar32. In such embodiments, the base40′M may be modified, such as providing a channel but without providing an opening therethrough, to accommodate any portion of one end of the locking bar32that may extend beyond the outer surface of the frame sidewall18′B.

In any case, the locking components12′ alone operate to lock the spool20from rotating in the web payout direction during locking conditions in the embodiment illustrated inFIG. 13. In contrast, rotation of the spool20in the web payout direction in the embodiment illustrated inFIGS. 1-12causes the locking components12to control the locking bar32to selectively lock the spool20from rotating in the web payout direction. Thus, in both of the illustrated embodiments, the locking components12,12′ cooperate with the spool shaft30to selectively lock rotation of the spool20. In the embodiment illustrated inFIGS. 1-12, the locking components12further control the position of the locking bar to selectively lock the spool relative to the frame18, whereas in the embodiment illustrated inFIG. 13the locking components12′ alone operate to selectively lock the spool relative to the frame18′.

Referring now toFIG. 14, a flowchart is shown of one illustrative process100for hermetically sealing locking components of a retractor. It will be understood that in the flowchart illustrated inFIG. 14, the steps are not necessarily executed in the sequence shown, and that one or more steps can include or be merged with one or more other steps. The process100is applicable to the embodiment illustrated inFIGS. 1-12and also to the embodiment illustrated inFIG. 13. In any case, the process100begins at step S1where the base40M,40′M is mounted to the retractor frame18,18′ using one or more of the mounting techniques described herein. At step S2, the sealing member(s)44and/or46is/are positioned about the opening(s)40D,40E,40′D in the housing40,40′. In embodiments which include a locking bar32and in which one of the locking components12engages the locking bar32, such a locking component is mounted to the locking bar32at step S3, shown in dashed-line form to indicate that step S3is executed only in certain embodiments. In any case, the locking components12,12′ are operatively arranged within the housing40,40′ at step S4, and at step S5the cover42is hermetically sealed to the open end of the housing40,40′ using one or more of the sealing techniques described hereinabove.

While the invention has been illustrated and described in detail in the foregoing drawings and description, the same is to be considered as illustrative and not restrictive in character, it being understood that only illustrative embodiments thereof have been shown and described and that all changes and modifications that come within the spirit of the invention are desired to be protected. For example, the concepts of this disclosure may alternatively still be used with locking retractors in which the locking components do not cooperate with the spool shaft30, but rather control the locking bar32to selectively lock the spool20from rotating in the web payout direction based only on conditions other than those associated with rotation of the spool20. Such conditions may include, for example, but should not be limited to, changes in inertia sensed by an apparatus such as the locking actuator54illustrated and described hereinabove, changes in position of the retractor relative to the direction of gravitational force, and the like. In such an embodiment, for example, the base40M of the housing40will define only a single opening40E therethrough with a sealing member44configured to extend about and engage the periphery of the opening40E such that the sealing member44forms a hermetic seal between one of the locking components and the opening40E of the housing. In this embodiment, the opening40D illustrated inFIGS. 1-12can be omitted, as can the sealing member46and the extended spool shaft30. To the extent the spool shaft30extends beyond the frame sidewall18B, the spool locking apparatus12will not engage or otherwise interface with the spool shaft30and in such embodiments, the base40M may be modified, such as providing a channel but without providing an opening therethrough, to accommodate any portion of the spool shaft30that may extend beyond the outer surface of the frame sidewall18B. In operation, the locking components12operate to lock and unlock rotation of the spool shaft30in the web payout direction strictly by controlling movement of the locking bar32relative to the frame18.