Method of assembling a tongue assembly for use with a seat belt system

A tongue assembly (10) is movable along seat belt webbing (16) and includes a latch plate sub-assembly (74) for engaging a buckle (26). A cinch bar (130) is carried by the latch plate sub-assembly (74) for pivotal movement relative to the latch plate sub-assembly between a disengaged position enabling the seat belt webbing and the latch plate sub-assembly to move relative to one another and an engaged position clamping the seat belt webbing against the latch plate sub-assembly. A method of assembling the tongue assembly (10) comprises the step of inserting a first end (138) of the cinch bar (130) into a first opening (128) in the latch plate sub-assembly (74) by movement of the cinch bar in a first direction (C). A second end (139) of the cinch bar (130) is inserted into a second opening (129) spaced away from the first opening (128) in the latch plate sub-assembly (74) by movement of the cinch bar in a second direction (E) opposite the first direction (C). The first end (138) of the cinch bar (130) is maintained in the first opening (128) while the second end (139) of the cinch bar is inserted in the second opening (129).

BACKGROUND OF THE INVENTION 
1. Technical Field 
The present invention relates to a method of assembling a tongue assembly 
for use in a vehicle seat belt system to help restrain movement of an 
occupant of a vehicle or of a child seat in a vehicle. 
2. Description of the Prior Art 
A known vehicle seat belt system is a three-point continuous loop seat belt 
system. A three-point continuous loop seat belt system includes a seat 
belt retractor and a length of belt webbing. The belt webbing extends from 
the retractor through a D-ring fixed to the vehicle and then down to an 
anchor point near the vehicle floor. A tongue assembly is slidable along 
the length of belt webbing between the D-ring and the anchor point. To use 
the seat belt system, a vehicle occupant grasps the tongue assembly and 
inserts it into a buckle. When the tongue assembly is fastened in the 
buckle, a portion of the belt webbing extends across the lap of the 
vehicle occupant and a portion of the belt webbing extends diagonally 
across the torso of the vehicle occupant. When the tongue assembly is 
released from the buckle, the belt webbing is wound onto the retractor. 
The tongue assembly should slide along the belt when the occupant moves the 
tongue assembly toward the buckle. The tongue assembly should also slide 
along the belt after the occupant unlocks the tongue assembly from the 
buckle so that the retractor can fully wind up the belt. The retractor 
would otherwise carry the tongue assembly upwardly to the D-ring, 
whereupon further movement of the belt would be prevented as the D-ring 
blocked further movement of the tongue assembly. Conversely, when the 
subject tongue assembly is locked in the buckle, it should cinch the belt 
webbing, that is, block movement of the belt webbing through the tongue 
assembly. This cinching action helps to restrain movement of the vehicle 
occupant in the event of a vehicle collision, and helps to secure a child 
seat in position on the vehicle seat. This cinch device is designed to 
cinch the webbing up to a predetermined load. Loads above the 
predetermined load may cause the webbing to translate but the occupant is 
still restrained. 
SUMMARY OF THE INVENTION 
The present invention is directed to a method of assembling a tongue 
assembly. The tongue assembly is movable along seat belt webbing and 
includes a latch plate sub-assembly for engaging a buckle and a cinch bar 
carried by the latch plate sub-assembly for pivotal movement relative to 
the latch plate sub-assembly between a disengaged position enabling the 
seat belt webbing and the latch plate sub-assembly to move relative to one 
another and an engaged position clamping the seat belt webbing against the 
latch plate sub-assembly. The method comprises the steps of inserting a 
first end of the cinch bar into a first opening in the latch plate 
sub-assembly by movement of the cinch bar in a first direction. A second 
end of the cinch bar is inserted into a second opening spaced away from 
the first opening in the latch plate sub-assembly. Movement of the cinch 
bar in a second direction opposite the first direction causes the cinch 
bar to be retained in the tongue assembly. The cinch bar is maintained in 
the latch plate sub-assembly by the seat belt webbing. Once retained in 
the latch plate sub-assembly by the seat belt webbing, the cinch bar can 
not be removed without breaking the parts. This design eliminates a 
separate pivot pinch for the cinch bar which is in the prior art.

DESCRIPTION OF PREFERRED EMBODIMENT 
The present invention relates to a method of assembling a tongue assembly 
for use in a vehicle seat belt system for helping to restrain movement of 
an occupant of the vehicle or of a child seat in the vehicle. 
FIG. 1 illustrates a tongue assembly 10 incorporated in a three-point 
continuous loop seat belt system 12 for use in helping to restrain an 
occupant of a vehicle or a child seat against movement relative to the 
vehicle. The following description assumes that the seat belt system 12 is 
used in restraining a vehicle occupant. It should be understood that the 
invention could be applied to other belt systems. 
During operation of the vehicle, the occupant of the vehicle sits on a seat 
14 which is illustrated as a front passenger seat in the vehicle. A length 
of seat belt webbing 16 is extensible about the vehicle occupant. One end 
of the length of belt webbing 16 is anchored to the vehicle body 18 at an 
anchor point 20 located on one side of the seat 14. The opposite end of 
the belt webbing 16 is attached to a seat belt retractor 22 which is 
secured to the vehicle body on the same side of the seat 14. Intermediate 
its ends, the belt webbing 16 passes through the tongue assembly 10 and a 
D-ring 24 that is located above the retractor 22 and the anchor point 20. 
When the seat belt system 12 is not in use, or is in its stowed condition, 
the belt webbing 16 is wound on the retractor 22 and is oriented generally 
vertically on the one side of the seat 14, as shown in solid lines in FIG. 
1. 
To engage the seat belt system 12, the tongue assembly 10 is manually 
grasped and is pulled across the lap and torso of the occupant sitting in 
the seat 14. As the tongue assembly 10 is pulled across the lap and torso 
of the occupant, the tongue assembly moves along the belt webbing 16, and 
the belt webbing is unwound from the retractor 22. When the belt webbing 
16 has been pulled across the lap and torso of the occupant, the tongue 
assembly 10 is connected with a buckle 26, as shown in dashed lines in 
FIG. 1. The buckle 26 is connected to the vehicle body 18 and is disposed 
on the side of the seat 14 opposite the anchor point 20. When the seat 
belt system 12 is thus buckled, the length of belt webbing 16 is divided 
by the tongue assembly 10 into a torso portion 28 which extends across the 
torso of the occupant and a lap portion 30 which extends across the lap of 
the occupant. 
The tongue assembly 10 (FIGS. 2-4) includes a metal plate member 34 which 
is preferably made of heat treated and chrome plated steel. The plate 
member 34 is a single piece of stamped metal and includes a generally 
planar leading end portion 36. The leading end portion 36 of the plate 
member 34 extends along a first plane 38 (FIG. 3). An opening 42 (FIG. 2) 
in the leading end portion 36 of the plate member 34 forms a buckle latch 
receiving opening in the tongue assembly 10. The opening 42 may be of any 
design. An optional opening 40 may be formed in the plate members to 
reduce the weight of the tongue assembly 10. 
The plate member 34 includes a generally planar trailing end portion 46 
which extends along a second plane 48 (FIG. 3). The second plane 48 is 
roughly parallel to, and offset from, the first plane 38. As a result, the 
trailing end portion 46 of the plate member 34 is roughly parallel to, and 
offset from, the leading end portion 36 of the plate member. 
A connector portion 50 (FIG. 2) of the plate member 34 extends at an angle 
between, and interconnects, the leading end portion 36 and trailing end 
portion 46 of the plate member. The connector portion 50 includes 
parallel, spaced apart first and second arm portions 54 and 56. The arm 
portions 54 and 56 lie in a connector plane which extends at an angle 
between the first plane 38 and the second plane 48. 
The leading end portion 36, the trailing end portion 46, the first arm 
portion 54, and the second arm portion 56 of the plate member 34 define a 
first belt webbing opening 60 in the tongue assembly 10. The first belt 
webbing opening 60 is disposed between the leading end portion 36 and the 
trailing end portion 46 of the plate member 34. The first belt webbing 
opening 60 has a width measured between the leading end portion 36 and the 
trailing end portion 46 of the plate member 34 which is sufficient to 
enable the belt webbing 16 (FIG. 3) to pass freely through the first belt 
webbing opening. 
The tongue assembly 10 also includes a body 70 of plastic material which 
covers most of the plate member 34 and which has portions which are 
located in the first belt webbing opening 60. The body 70 of plastic 
material is molded from nylon, preferably Zytel.RTM. (trademark of E.I. 
Dupont de Nemours & Co.) brand plastic. The body 70 of plastic material is 
insert molded as one piece on the metal plate member 34 by a known 
process. Together the plate member 34 and the body 70 of plastic material 
form a latch plate sub-assembly 74 (FIG. 6). 
The body 70 of plastic material includes a leading end portion 76 which 
covers a part of the leading end portion 36 of the plate member 34. The 
leading end portion 76 of the body 70 of plastic material has first and 
second major side surfaces 78 and 80 (FIG. 3) spaced apart generally an 
equal distance on opposite sides of the first plane 38. 
The leading end portion 76 of the body 70 of plastic material has a first 
webbing guiding surface 84. The first webbing guiding surface 84 is planar 
and extends in a plane which is skewed at an angle of about 60 with 
respect to the first plane 38. A first arcuate connector surface 86 
extends between and interconnects the first webbing guiding surface 84 and 
the first major side surface 78 of the leading end portion 76 of the body 
70 of plastic material. 
The leading end portion 76 of the body 70 of plastic material also has a 
planar clamping surface 90. The clamping surface 90 extends along the 
first webbing guiding surface 84 at an angle of about 55.degree. with 
respect to the first plane 38. A second arcuate connector surface 86a 
extends between and interconnects the clamping surface 90 and the second 
major side surfaces 80 of the leading end portion 76 of the body 70 of 
plastic materials. The clamping surface 90 and the second arcuate 
connector surface 86a interconnect the first webbing guiding surface 84 
with the second major side surface 80 of the leading end portion 76 of the 
body 70 of plastic material. 
The body 70 of plastic material also includes a trailing end portion 96 
which covers the trailing end portion 46 of the plate member 34. The 
trailing end portion 96 of the body 70 of plastic material has first and 
second major side surfaces 98 and 100 spaced apart on opposite sides of 
the second plane 48. An arcuate, concave support surface 104 extends from 
the second major side surface 100 of the trailing end portion 96 in a 
direction toward the first major side surface 98 of the trailing end 
portion 96. The support surface 104 has a center of curvature located on a 
longitudinally extending first central axis 106 of the tongue assembly 10. 
A planar second webbing guiding surface 110 extends from the first major 
side surface 98 of the trailing end portion 96 in a direction toward the 
second major side surface 100 of the trailing end portion 96. The second 
webbing guiding surface 110 lies in a plane which is skewed with respect 
to the second plane 48 and also with respect to the first webbing guiding 
surface 84. 
A planar connecting surface 112 extends transversely between, and 
interconnects, the second webbing guiding surface 110 and the support 
surface 104. The connecting surface 112 is generally parallel to, and 
spaced apart from, the planar clamping surface 90 of the leading end 
portion 76 of the body 70 of plastic material. 
The body 70 of plastic material also includes a connector portion 120 (FIG. 
2). The connector portion 120 includes spaced apart first and second arm 
portions 122 and 124 (FIG. 2) which cover the first and second arm 
portions 54 and 56 of the plate member 34. 
The first arm portion 122 of the body 70 of plastic material is partially 
defined by a planar first side wall 114 (FIG. 5). The first arm portion 
122 includes a first cylindrical opening 128. The first cylindrical 
opening 128 extends axially from the first side wall 114, away from the 
second arm portion 124, to the exterior of the body 70 of plastic 
material. The first cylindrical opening 128 is centered on the first axis 
106. 
The first arm portion 122 includes a notch 126 adjacent to the first 
cylindrical opening 128 and presented toward the second arm portion 124. 
The notch 126 is defined in part by a planar first surface 200, a planar 
second surface 202, and a planar third surface 204. The first surface 200 
extends axially from the first side wall 114, away from the second arm 
portion 124, to the third surface 204. The second surface 202 extends 
transverse to the first surface 200 and axially to the third surface 204. 
The third surface 204 is parallel to, and spaced apart from, the first 
side wall 114. 
The second arm portion 124 of the body 70 of plastic material is partially 
defined by a planar second side wall 118. The second side wall 118 is 
parallel to, and spaced apart from, the first side wall 114 by a first 
distance. The second side wall 118 includes a second cylindrical opening 
129 spaced apart from the first cylindrical opening 128. The second 
cylindrical opening 129 extends axially from the second side wall 118 away 
from the first side wall 114 and is centered on the first axis 106. 
The clamping surface 90 (FIG. 3), the first webbing guiding surface 84, and 
the connector surfaces 86 and 86a of the leading end portion 76, the 
support surface 104, the second webbing guiding surface 110, and the 
connecting surface 112 of the trailing end portion 76, and the first side 
wall 114 and the second side wall 118 of the connector portion 120 
together define a second belt webbing opening 116 in the body 70 of 
plastic material. The second belt webbing opening 116 is disposed between 
the leading end portion 76 and the trailing end portion 96 of the body 70 
of plastic material. The second belt webbing opening 116 has a width 
measured between the leading end portion 76 and the trailing end portion 
96 of the body 70 of plastic material which is smaller than the width of 
the first belt webbing opening 60 but is sufficient to enable the belt 
webbing 16 to pass freely through the opening 116. The length of the 
second belt webbing opening 116 is equal to the first distance in the 
latch plate sub-assembly 74 that, is, the distance between the first side 
wall 114 and the second side wall 118 of the connector portion 120. 
The tongue assembly 10 includes a cinch bar 130 (FIG. 2). The cinch bar 130 
includes a body portion 134 extending axially between a first end 220 and 
a second end 230. The first end 220 of the cinch bar 130 includes a planar 
first end wall 132 and a planar second end wall 133, which is parallel to 
and spaced apart a second distance from the first end wall. The second end 
230 of the cinch bar 130 includes a planar third end wall 137, which is 
parallel to and spaced apart from the first end wall 132 by a third 
distance and from the second wall 133 by a fourth distance, respectively. 
The fourth distance is slightly less than the first distance in the latch 
plate sub-assembly 74. 
The body portion 134 of the cinch bar 130 includes a projection key or key 
portion 136 that extends axially from the first end wall 132 of the cinch 
bar 130. The key portion 136 has a shape complementary to the notch 126. 
The key portion 136 is defined in part by a planar fourth surface 210 
extending axially between the first end wall 132 and the second end wall 
133. The key portion 136, thus, has an axial length equal to the second 
distance, which is slightly less than the axial length of the notch 126. 
It is contemplated that the key portion 136, and thus, the notch 126, 
could have shapes differing from that which is described herein. 
The body portion 134 of the cinch bar 130 includes an arcuate belt webbing 
clamping surface 140 (FIG. 3) and a cinch bar actuation surface 144. An 
arcuate inner side surface 146 and an arcuate outer side surface 148, 
having centers of curvature on the first axis 106, extend between and 
interconnect the belt webbing clamping surface 140 and the cinch bar 
actuation surface 144. A plurality of radially extending ribs (not shown) 
are spaced apart at intervals over the length of the cinch bar body 
portion 134. Each rib has the cross-sectional configuration of the body 
portion 134 as a whole. The cinch bar 130 is molded in this manner in 
accordance with known molding practices. 
The belt webbing clamping surface 140, the inner side surface 146, and the 
outer side surface 148 all extend axially between the first end wall 132 
and the third end wall 137 and, thus, have axial lengths equal to the 
third distance. The cinch bar actuation surface 144 has an axial length 
slightly less than the fourth distance and has a portion extending between 
and connecting opposite ends of the fourth surface 210, thus helping to 
define the key portion 136. 
The cinch bar actuation surface 144 includes a curved belt webbing engaging 
surface 150 extending from the inner side surface 146 towards the outer 
side surface 148. The cinch bar actuation surface 144 also includes a 
planar stop surface 152 which extends between and interconnects the belt 
webbing engaging surface 150 and the arcuate outer side surface 148 of the 
cinch bar 130. The radial distance between the major portion of the stop 
surface 152 and the first axis 106 is greater than the radial distance 
between the arcuate outer side surface 148 and the first axis. 
The cinch bar 130 includes a first pivot pin 138 (FIG. 2) and a second 
pivot pin 139. The first pivot pin 138 is defined by a first cylindrical 
surface 170 extending axially between the first end wall 132 and a first 
circular wall 172. The first circular wall 172 is parallel to, and spaced 
apart a fifth distance, greater than the second distance, from the first 
end wall 132. The first pivot pin 138 is adjacent to the key portion 136 
and is centered on a longitudinally extending second central axis 142. 
The second pivot pin 139 is defined by a second cylindrical surface 174 
extending axially between the third end wall 137 and a second circular 
wall 176. The second circular wall 176 is spaced apart a sixth distance, 
less than the fifth distance, from the third end wall 137. The second 
pivot pin 139 is centered on the second axis 142. 
The first and second pivot pins 138 and 139 are disposed in the first and 
second cylindrical openings 128 and 129, respectively, in the latch plate 
sub-assembly 74. The first and second pivot pins 138 and 139 support the 
cinch bar 130 for pivotal movement about the first axis 106. The axial 
length of the cinch bar 130, or the distance between the first circular 
wall 172 and the second circular wall 176 is equal to a seventh distance, 
greater than the first distance. 
The cinch bar 130 is preferably molded from Acetal.RTM. (trademark of 
Celenese Plastics Corp.) brand plastic. The cinch bar 130 is preferably 
molded as one piece of plastic but may, alternatively, be formed as two 
pieces (not shown) with the body portion 134 having a central longitudinal 
opening for receiving a separate pivot pin which may be made of another 
material. 
FIG. 3 illustrates the parts of the tongue assembly 10 in an unlocked 
condition. The belt webbing 16 of the seat belt system 12 (FIG. 1) is in 
its stowed condition and the tongue assembly 10 is adjacent the D-ring 24. 
The belt webbing 16 extends through the tongue assembly 10 in a relatively 
straight condition. The cinch bar 130 is in a disengaged position on the 
tongue assembly 10 in which the belt webbing 16 is located between the 
cinch bar 130 and the leading end portions 36 and 76 of the plate member 
34 and the body 70 of plastic material, respectively as shown in FIG. 3. 
When the cinch bar 130 is in the disengaged position, the belt webbing 
clamping surface 140 of the cinch bar is spaced apart from the clamping 
surface 90 of the body 70 of plastic material by an eighth distance. 
To engage the seat belt system 12 (FIG. 1), the vehicle occupant grasps the 
leading end portion 36 of the plate member 34 of the tongue assembly 10 
with the buckle 26. The vehicle occupant then pulls on the tongue assembly 
10 until enough of the belt webbing 16 passes through the tongue assembly 
10 to make the lap portion 30 fit tightly around the occupant's lap. The 
vehicle occupant then inserts the tongue assembly 10 into the buckle 26 so 
that the seat belt system 12 is in the buckled condition as shown in 
dashed lines in FIG. 1. 
As the seat belt system 12 is moved into the buckled condition, the belt 
webbing 16 partially wraps around, or encircles, the cinch bar 130 and 
assumes a U-shape within the tongue assembly 10. Both the lap portion 30 
and the torso portion 28 of the belt webbing 16 extend from the cinch bar 
130 of the tongue assembly 10 in an upward direction as viewed in FIG. 4. 
The lap portion 30 of the belt webbing 16 is tight around the occupant's 
lap and is under tension from the anchor point 20. This tensile force acts 
on the lap portion 30 of the belt webbing 16 in an upward direction 
indicated by the arrow A in FIG. 4. The torso portion 28 of the belt 
webbing 16 is also under tension from a retraction force applied by the 
retractor 22. 
As the belt webbing 16 wraps around the cinch bar 130, a first portion 160 
(FIG. 4) of the belt webbing frictionally engages the belt webbing 
engaging surface 150 of the cinch bar 130. The first portion 160 of the 
belt webbing 16 transfers force from the belt webbing to the cinch bar 
130. This eccentric force causes the cinch bar 130 to pivot in a direction 
indicated by the arrow B, that is, clockwise as viewed in FIGS. 3 and 4. 
The support surface 104 of the body 70 of plastic material helps to guide 
the pivotal movement of the cinch bar 130 and supports the cinch bar under 
high loads. 
As the cinch bar 130 pivots in the direction B, the belt webbing clamping 
surface 140 frictionally engages a second portion 162 of the belt webbing 
16. Together with the second portion 162 of the belt webbing, the belt 
webbing clamping surface 140 moves toward the leading end portion 76 of 
the tongue assembly 10 along an arcuate path having a center of curvature 
on the first axis 106. The cinch bar 130 pivots in the direction B until 
the clamping force exerted on the belt webbing 162 by the clamping 
surfaces 90 and 140 balances the pivoting force applied to the belt 
webbing engaging surface 150. 
The cinch bar 130 is then in an engaged position as shown in FIG. 4. When 
the cinch bar 130 is in the engaged position, the belt webbing clamping 
surface 140 of the cinch bar is spaced from the clamping surface 90 of the 
body 70 of plastic material by a ninth distance, which is less than the 
eighth distance. The belt webbing clamping surface 140 of the cinch bar 
130 clamps the second portion 162 of the belt webbing 16 against the 
clamping surface 90 of the body 70 of plastic material on the tongue 
assembly 10. 
The clamping of the belt webbing 16 against the clamping surface 90 of the 
body 70 of plastic material blocks movement of the belt webbing 16 through 
the tongue assembly 10 in the direction A. Thus, the belt webbing 16 is 
clamped by the cinch bar 130 in the tongue assembly 10, and the lap 
portion 30 of the belt webbing cannot normally be lengthened. 
The force applied to the lap portion 30 of the belt webbing 16 may be 
increased substantially if the vehicle decelerates suddenly and the 
vehicle occupant's momentum causes the occupant to move forward relative 
to the seat 14. The parts of the tongue assembly 10 can be configured so 
that, if this occurs, the belt webbing 16 may slip through the tongue 
assembly to balance the load on the torso portion 28 and the lap portion 
30 of the seat belt system 12. This may happen if the force on the belt 
webbing 16 exceeds a predetermined level, for example, about 120 pounds. 
When the vehicle occupant unbuckles the seat belt system 12, the tension on 
the lap portion 30 of the belt webbing 16 is released. The retractor 22 
pulls on the belt webbing 16 and winds belt webbing on the retractor to 
return the seat belt system 12 to the stowed condition as shown in FIG. 1. 
The retractor 22 also pulls the belt webbing 16 through the tongue 
assembly 10. In response to movement of the webbing 16, the tongue 
assembly 10 returns to its unlocked condition and the cinch bar 130 pivots 
back to the disengaged position shown in FIG. 3. 
The foregoing description assumes that the seat belt system 12 (FIG. 1) is 
used for restraining a vehicle occupant in the seat 14. As noted above, 
the seat belt system 12 (FIG. 1) can also be used for restraining a child 
seat (not shown) in the seat 14. The seat belt system 12, when used for 
restraining a child seat in the seat 14, is buckled so that the lap 
portion 30 of the belt webbing 16 holds the child seat on the vehicle seat 
14. The tongue assembly 10 clamps the seat belt webbing 16 so that the lap 
portion 30 of the belt webbing cannot be lengthened. Thus, the child seat 
is securely held in position on the vehicle seat 14 and does not move 
relative to the vehicle seat during vehicle maneuvering. 
To assemble the tongue assembly 10 (FIGS. 5-12), the first end 220 of the 
cinch bar 130 is moved in a first assembly direction, as indicated by the 
arrow C, towards the first side wall 114 and into the second belt webbing 
opening 116, as shown by FIG. 5. A first amount of force is used to move 
the cinch bar 130 in the direction C to slide the first pivot pin 138 of 
the cinch bar 130 into the first cylindrical opening 128 and 
simultaneously to slide the key portion 136 into the notch 126. 
Since the axial length of the cinch bar 130 is greater than the axial 
length of the second belt webbing opening 116, the cinch bar 130 must be 
angled with respect to the first axis 106 as it is moved in the direction 
C. This angled orientation may cause portions of the cinch bar 130 to 
frictionally engage portions of the latch plate sub-assembly 74 to varying 
degrees. Examples may include; as the cinch bar 130 is moved in the 
direction C, (i) the first pivot pin 138 may frictionally engage the 
surface defining the first cylindrical opening 128, (ii) the fourth 
surface 210 (FIG. 6) of the cinch bar may frictionally engage the first 
surface 200 of the notch 126, and (iii) the second pivot pin 139 (FIG. 5) 
may frictionally engage the second arm portion 124 of the connector 
portion 120. Frictional forces between the cinch bar 130 and the latch 
plate sub-assembly 74 may inhibit movement of the cinch bar in the 
direction C such that the movement of the cinch bar in the direction C 
ceases upon the application of the first amount of force, leaving the 
cinch bar in a first assembling position as shown in FIGS. 5 and 6. 
In the first assembling position, most of the first end 220 of the cinch 
bar 130 is disposed in the second belt webbing opening 116 so that a first 
portion of the first pivot pin 138 is inserted within the first 
cylindrical opening 128 and a first portion of the key portion 136 is 
inserted within the notch 126. 
With respect to the key portion 136, as the cinch bar 130 is being moved in 
the direction C to the first assembling position, the cinch bar 130 must 
be oriented such that the fourth surface 210 (FIG. 6) of the key portion 
136 of the cinch bar is facing, and engages, the first surface 200 of the 
notch 126. In other words, when the cinch bar 130 is being moved in the 
direction C, the cinch bar must be oriented such that the first pivot pin 
138 is presented towards the first side wall 114. As explained below in 
detail, this orientation is necessary for proper assembly of the tongue 
assembly 10. 
When in the first assembling position, the second end 230 of the cinch bar 
130 is outside of, or spaced apart from, the second belt webbing opening 
116 such that the second pivot pin 139 lies on top of the second arm 
portion 124 of the connector portion 120 of the body 70 of plastic 
material. Thus, in the first assembling position, the cinch bar 130 is 
angled with respect to the second belt webbing opening 116 such that the 
second axis 142 of the cinch bar 130 is skewed with respect to the first 
axis 106, as shown in FIG. 5. 
A second amount of force, greater than the first amount of force, may then 
be exerted in the direction C on the second end 230, or the third end wall 
137, of the cinch bar 130. The second amount of force is sufficient to 
overcome any frictional forces between the cinch bar 130 and the latch 
plate sub-assembly 74 and moves the cinch bar further in the direction C 
towards the first side wall 114. Continued movement of the cinch bar 130 
in the direction C disengages the second pivot pin 139 from the second arm 
portion 124 and allows the second end 230 of the cinch bar to be moved in 
a second assembling direction, transverse to the direction C, as indicated 
by the arrow D, into the second belt webbing opening 116 to a second 
assembling position as shown in FIGS. 7 and 8. Because the first pivot pin 
138 is longer than the second pivot pin 139, the cinch bar 130 cannot be 
assembled into the latch plate sub-assembly 74 if the cinch bar is 
reversed end for end. 
In the second assembling position, the first end 220 of the cinch bar 130 
is disposed in the second belt webbing opening 116 so that a second 
portion of the first pivot pin 138 is disposed within the first 
cylindrical opening 128 and a second portion of the key portion 136 is 
partially disposed within the notch 126. The second portions of the first 
pivot pin 138 and the key portion 136 are greater than the first portions 
of the first pivot pin and the key portion, respectively. Preferably, the 
second portion of the first pivot pin 138 is substantially all of the 
first pivot pin and the second portion of the key portion 136 is 
substantially all of the key portion. 
Also, when the cinch bar 130 is in the second assembling position, the 
second axis 142 of the cinch bar 130 is coincident with the first axis 106 
as shown in FIGS. 7 and 8. When the cinch bar 130 is in the second 
assembling position, the second pivot pin 139 is aligned with, but spaced 
axially outside of, the second cylindrical opening 129. 
A third amount of force, substantially smaller than the first or second 
amounts of force, is then exerted on the cinch bar 130 to move, or slide, 
the cinch bar towards the third side wall 118 in a third assembling 
direction, indicated by the arrow E to a third assembling position as 
shown by FIGS. 9 and 10. The third assembling direction E is generally 
opposite the first assembling position C. As the cinch bar 130 is moved to 
the third assembling position, the second pivot pin 139 slides into the 
second cylindrical opening 129. 
In the third assembling position, the entire body portion 134 of the cinch 
bar 130 is disposed in the second belt webbing opening 116. A third 
portion of the first pivot pin 138, less than the second portion, is 
disposed within the first cylindrical opening 128. A portion of the second 
pivot pin 139 is disposed within the second cylindrical opening 129. The 
key portion 136 is located in the second belt webbing opening 116 and is 
spaced apart axially from the notch 126, as best seen in FIG. 9. With the 
key portion 136 being spaced apart axially from the notch 126, the fourth 
surface 210 (FIG. 10) of the cinch bar 130 is disengaged, or spaced apart 
axially, from the first surface 200 of the notch 126, thereby allowing 
pivotal movement of the cinch bar on the first axis 106. 
It is important to note that as the cinch bar 130 is being moved in the 
direction E to the third assembling position, a portion of the first pivot 
pin 138 remains disposed within the first cylindrical opening 128 at all 
times. Thus, the second pivot pin 139 is inserted within the second 
cylindrical opening 129 while a portion of the first pivot pin 138 remains 
disposed within the first cylindrical opening 128. 
The cinch bar 130 is then pivoted, or rotated, in a counterclockwise 
direction as indicated by the arrow F to a fourth assembling position as 
shown in FIGS. 11 and 12. In the fourth assembling position, both the 
first and second pivot pins 138 and 139 have portions which remain 
disposed axially within the first and second cylindrical openings 128 and 
129, respectively, in a manner which is essentially identical to that in 
the third assembling position. In the fourth assembling position, the key 
portion 136 causes the first end wall 132 of the cinch bar 130 to be 
spaced at least about the second distance from the first side wall 114 of 
the body 70 of plastic material as in the third assembling position. In 
the fourth assembling position, the key portion 136 is thus also spaced 
angularly about the first axis 106 from the notch 126. This angular and 
axial separation of the key portion 136 from the notch 126 prevents the 
cinch bar 130 from moving back into the second assembling position. 
While the cinch bar 130 is in the fourth assembling position, a clearance 
exists in the second belt webbing opening 116 between the body portion 134 
of the cinch bar and the leading end portion 76 of the body 70 of plastic 
material. The clearance is wider than the thickness of the belt webbing 
16. This enables the belt webbing 16 to be inserted through the second 
belt webbing opening 116 to enable use of the tongue assembly 10 with the 
seat belt system 12. 
When the belt webbing 16 is disposed within the second belt webbing opening 
116 as shown in FIGS. 11 and 12, the thickness of the belt webbing 
prevents the cinch bar 130 from pivoting back to the third assembling 
position. Thus, the key portion 136 cannot be shifted back into the notch 
126. The first and second pivot pins 138 and 139 remain disposed within 
the first and second cylindrical openings 128 and 129, respectively, and 
the cinch bar 130 cannot be removed from the latch plate sub-assembly 74. 
The tongue assembly 10, as assembled, is then ready for use with the seat 
belt system 12. 
The axial lengths of the first pivot pin 138, the second pivot pin 139, the 
body portion 134 of the cinch bar 130, and the second belt webbing opening 
116 are such that the axial length of the clearance that exists between 
the second end wall 133 of the cinch bar and the first side wall 114 of 
the body 70 of plastic material, when the third end wall 137 abuts the 
second side wall 118, is less than the axial length of the portion of the 
first pivot pin 138 which is disposed within the first cylindrical opening 
128. The axial length of the clearance that exists between the third end 
wall 137 of the cinch bar 130 and the second side wall 118 of the body 70 
of plastic material, when the second end wall 133 abuts the first side 
wall 114, is less than the axial length of the portion of the second pivot 
pin 139 which is disposed within the second cylindrical opening 129. The 
clearances being less than the portions of the first and second pivot pins 
138 and 139 disposed within the first and second cylindrical openings 128 
and 129, respectively, ensures that the cinch bar 130 remains supported on 
the latch plate sub-assembly 74, and does not fall out of the second seat 
belt webbing opening 116, when the cinch bar is in the fourth assembling 
position. 
From the above description of the invention, those skilled in the art will 
perceive improvements, changes and modifications in the invention. For 
example, the configuration of the body of plastic material may be altered 
from the free-falling configuration to a free-running configuration. Such 
improvements, changes and modifications within the skill of the art are 
intended to be covered by the appended claims.