Seatbelt anchor assembly

A seatbelt anchor assembly for a motor vehicle seatbelt restraint system. The anchor assembly includes an anchor and a separate ferrule component. The anchor forms an engagement for the seatbelt and has an extending plate end. The ferrule component is adapted to be mounted to the vehicle through various means such as cable or direct mechanical fastener attachment. The ferrule forms a U-shaped cross-section which engages with the anchor and interlocks with it. In one embodiment, a retaining clip is provided enabling the anchor and ferrule components to be assembled without tools. A pair of holes is provided to enable final connection to be provided through a threaded fastener. Features are provided to prevent to make it apparent that the components are improperly assembled.

FIELD OF THE INVENTION

This invention relates to a seatbelt anchor assembly adapted for use as part of a motor vehicle seatbelt restraint assembly.

BACKGROUND OF THE INVENTION

Seatbelt assemblies are in widespread use in motor vehicles. Present systems have certain common elements including seatbelt webbing which extends across the upper and lower torso of the occupant, and a retractor for allowing protraction and retraction of the webbing so that the belt may adapt to different sizes of occupants and be conveniently out of the way when not being used. Seatbelt assemblies further typically include a buckle which releasably attaches to a latch plate. Other common elements include deflectors or D-rings which reroute the webbing to properly position it with respect to the occupant to provide the desired restraint performance along with comfort and convenience of use.

Seatbelt assemblies must be securely affixed to motor vehicle structural elements in order to provide the necessary restraint effect in vehicle impact conditions and further to meet government regulations. Most frequently, elements of the seatbelt assembly are mounted to the vehicle structure such as the floor pan, roof rail, body pillars, or seats using threaded fasteners. For some designs of seatbelt systems, it is necessary to affix two components together to provide an anchor assembly and the two parts may be attached together at various stages of an assembly process and perhaps at different locations. For such applications, an anchor component is provided which is affixed to the seatbelt webbing and may for example include a D-ring or aperture for receiving belt webbing, which is connected with a separate ferrule or other mounting element adapted to be affixed to the vehicle. Since these parts are separate, they must be assembled at some point in the assembly process. Moreover, some designs of seatbelt restraint systems must be adapted for mounting to various types of vehicle applications. For example, in some instances an anchor is bolted directly to a vehicle structure element through a metal connector strap having an aperture for receiving a mounting bolt. In other applications, a cable having an end affixed to the motor vehicle and another end affixed to the anchor is used. It is desirable to provide a seatbelt anchor assembly which can be readily adapted for both strap and cable mounting applications as well as other potential mounting applications.

Since it is often necessary to mate the above-mentioned components of an anchor assembly for such applications, it is desirable that these parts can be fitted together during the assembly process and maintained in an attached condition until final attachment and securement of the components can be accomplished. By retaining these parts together, they are maintained in an assembled condition.

Since seatbelt anchor assemblies must bear significant tensile forces during operation and testing, the two components which mate together to form the anchor assembly must be structurally robust in order to meet these requirements, and their proper assembly should be easily attained and visually apparent.

A seatbelt anchor assemblies in accordance with this invention provide the above-mentioned features of adaptability, ease of assembly, and structural integrity.

Additional benefits and advantages of the present invention will become apparent to those skilled in the art to which the present invention relates from the subsequent description of the preferred embodiment and the appended claims, taken in conjunction with the accompanying drawings.

DETAILED DESCRIPTION OF THE INVENTION

A seatbelt anchor assembly in accordance with the first embodiment of this invention is illustrated inFIGS. 1 and 3. The anchor assembly includes a pair of primary structural components, including anchor12, ferrule14, and further has retaining clip16.FIG. 1illustrates these components in an assembled position, whereasFIG. 3shows the parts in an exploded apart position.

Anchor12is preferably formed from sheet metal stock and includes a connection end18which, in the embodiment illustrated, includes a central aperture20adapted to receive seatbelt webbing (not shown). Connection end18could alternatively mount a belt buckle or other belt restraint system component. Preferably, if webbing is routed through aperture20, the edges of the aperture would feature rounded edges or, in some cases, a resin coating is used to provide smooth motion of the webbing through the aperture and prevents tearing or gouging of the webbing when it is under load. Anchor12further includes a projecting plate end22. In a preferred embodiment, plate end22includes a mid-section24and an end section26. The end section26is wider than the mid-section24, thereby forming a pair of shoulder surfaces28and30. As it will be explained in more detail in the later description, it is preferred that shoulder surfaces28and30be “misaligned” or at different positions along the length of anchor12to prevent misassembly of the components. Anchor12further forms hole32adapted to receive a threaded fastener when the components are in their final assembled condition. The edges of anchor mid-section24are shown having a relieved radius edge36which provides clearance for mating contact with ferrule14.

Ferrule14is also formed preferably from sheet metal stock and includes an end section38which is U-shaped in cross-section. End38forms a plate section40and a pair of rolled sides42and44, each preferably forming extending hooks46and48, and notches50and52. Plate40further forms hole54which is oriented to align with hole32when the components are in their assembled condition for receiving a fastener such as threaded bolt74.

In order to permit anchor assembly10to be adapted for various vehicle applications, ferrule14in a first embodiment forms a cable crimping sleeve56. Sleeve56has a hollow interior for receiving a mounting cable (not shown) and can be crushed to firmly affix the cable to ferrule14. Another end of the cable is mounted to a vehicle structural component.

In another embodiment of the invention illustrated inFIG. 2, ferrule14A features and extending strap58having a mounting aperture60. Strap58can be directly mounted to a vehicle structural element through a threaded fastener connection passing through mounting aperture60.

As illustrated particularly inFIGS. 1 and 3, retaining clip16includes a central bridge section64and a pair of V-shaped legs66and68. The inner surfaces of legs66and68preferably includes ramp projections70and72such that clip16can be snapped into engagement with anchor12. This occurs as the ramps70and72deflect as the clip is installed and snap against the face surface of anchor opposite the surface where bridge64is present. Anchor notches71and73receive ramps70and72to locate clip16.FIG. 2shows the position of retaining clip16as it would be installed into snap connection engagement with anchor12. Once clip16is assembled, it is maintained in connection with anchor12.

Ferrule14is assembled in connection with anchor12by sliding them together in a manner causing compression of clip legs66and68enabling hooks46and48to clear shoulders28and30. Once in this position, tension is applied to the parts causing them to move to their assembled position illustrated inFIG. 1. In this position, as best shown byFIG. 4, hooks46and48interlock with anchor end section26. Retaining clip legs66and68provide a compliant force urging anchor12and ferrule14into their assembled position as shown inFIG. 1. In this assembled condition, the assembly may be handled and shipped and later threaded fastener74may be installed.

Since ferrule14is formed of sheet metal, a radius is formed at the junctions between plate section40and sides42and44. When the parts are assembled, relieved edges36of anchor12provide clearance to accommodate the inside radii of ferrule14.

As illustrated inFIG. 3, shoulder surfaces28and30are positioned at different positions along the length of anchor12. The corresponding engaging surfaces of ferrule14are also misaligned in the same manner as are the shoulder surfaces. Thus, in a properly assembled condition, the components will reach the position shown inFIG. 1in which case holes32and54align to receive the threaded fastener74, shown inFIG. 4as bolt74. However, if the parts are assembled improperly with the anchor12or ferrule14in an upside down position, the parts cannot reach their assembled condition as illustrated inFIG. 7. As shown in that figure, holes32and54do not align and one of the hooks48does not engage the anchor shoulder30, indicating improper assembly. The parts only fit together when ferrule plate40is placed against one face surface of anchor mid section24, and not when placed against the opposite face surface.

During the assembly process, ferrule14may be affixed to anchor12in the manner described above and handled as part of a seatbelt assembly. When the final assembly process is completed for the seatbelt system, threaded fastener74is installed through holes32and54. As best illustrated inFIG. 4, the interlocking connection between these components provides a high strength mechanical connection between them able to restrain the forces acting on these components during use and in compliance with government regulations. Depending on the application, either configuration of ferrule14or14A may be used with anchor17.

A seatbelt anchor in accordance with a third embodiment of this invention is illustrated inFIGS. 8 through 11. This anchor assembly80forms a pair of primary structural components similar to that of the first and second embodiments including anchor82and ferrule84. This embodiment however, does not employ an element corresponding with retainer clip16described and shown in connection with the first and second embodiments.FIGS. 8 through 11illustrate these components in an assembled condition. Anchor82is preferably formed from sheet metal stock and includes a connection end86, which in the embodiment illustrated forms a central aperture88adapted to receive seatbelt webbing (not shown) for connection with an associated belt restraint system. Anchor82further forms a projecting plate end90forming mid-section92and end section94. End section94is wider than mid-section92thereby forming a pair of shoulder surfaces96and98. Anchor82further forms hole102adapted to receive a threaded fastener when the components are in their final assembled condition. Between connection end86and plate end90, anchor82forms a narrowed neck section91.

Ferrule84is also preferably formed from sheet metal stock and includes end section104which is U-shaped in cross-section. End104forms a plate section106and a pair of rolled sides108and110, each forming hooks112and114extending toward cable sleeve130, and notches116and118. Rolled sides108and110further form a second pair of hooks132and134with end bent toward the center of plate section106. Plate106further forms hole120which is oriented to align with hole102when the components are in their assembled condition for receiving a fastener such as threaded bolt74. Bushing124is welded to ferrule plate section106to provide additional thread engagement with fastener74, to increase the clamping and retention force provided by the fastener. Fastener74is not shown with anchor assembly80but would be inserted through hole102to engage with bushing124. In other words, the fastener would be inserted into engagement with the assembly as the components are shown inFIG. 8.

Anchor end section94forms side edge sections126and128which are bowed or deflected toward ferrule plate section106. This feature is best illustrated inFIGS. 10 and 11.

Like the first embodiments, anchor assembly80includes features to prevent improper assembly of anchor82and ferrule84. The proper assembled condition is illustrated inFIGS. 8 through 11. Anchor82and ferrule84are mated together and then pulled apart such that they slide relative each other until ferrule84and hooks112and114engage with shoulders96and98. In this assembled condition, hooks132and134, which fit into anchor neck section91when the parts are being assembled, also overlap the anchor mid-section92. As best shown inFIG. 11, edges126and128, having their formed curled configuration, allow hooks112and114to interlock with them. Once in the final assembled condition shown inFIGS. 10 and 11, a threaded fastener74may be placed through holes102and120engaging with bushing124.

Improper assembly of anchor assembly80is prevented since if an attempt were made to invert ferrule84, the curled edges126and128would interfere with hooks112and114. This would prevent the parts from reaching their final assembled condition in which holes102and120align, and thus placement of the fastener84is prevented.

In order to permit anchor assembly80to be mounted to the vehicle, ferrule84in the embodiment shown inFIGS. 8 through 11, forms a cable crimping sleeve122which is similar to ferrule14in accordance with the first embodiment of this invention. As illustrated in the descriptions of the first and second embodiment, ferrule84could also be adapted to include a strap for mounting to the vehicle or some other feature for mounting could be provided.

This description defines a configuration of anchors12and82and ferrules14and84and their interengagement. It is recognized that the features of one of these components may be provided on the other component while achieving the aims and features of this invention. Thus ferrule14or84could, in such an alternative configuration, have the features of anchor plate end22or90, with the anchor12or82having the “U”-shaped cross-section shape with the sides and hooks described for the ferrule.