Abstract:
A seat belt retractor mounting system for a vehicle seat includes a bracket having a first sidewall and a second sidewall. A generally planar plate is located generally parallel to and spaced apart from the first sidewall of the bracket. The plate is coupled to the second sidewall. In addition, at least one of the bracket and plate are secured to, and cooperate with, a seat cushion frame of the seat to surround and protect an emergency locking retractor mounted to the first sidewall. A method employs the system.

Description:
This application is a continuation of U.S. patent application Ser. No. 11/468,738, filed Aug. 30, 2006, the entire contents of which are hereby incorporated herein by reference thereto. 

   FIELD 
   The present invention relates generally to vehicle occupant restraints, in particular to a mounting system for a seat-mounted emergency locking retractor. 
   BACKGROUND 
   Vehicle occupant restraints, including seat belt devices, are important and well-known components of vehicle safety systems. If a vehicle experiences a severe impact a properly belted-in occupant is generally held in place by the seat belt&#39;s webbing, thereby avoiding many serious, if not fatal, physical collisions with the vehicle interior and/or being ejected from the vehicle. Since their introduction seat belts have saved countless lives and reduced the severity of injury in countless more. 
   Current seat-mounted occupant restraint systems often locate the seat belt emergency locking retractor on the frame of the seat cushion and route the seat belt webbing upwardly along a rear portion of the seat back. However, locating the retractor in this manner may expose it to contact with rear seat passengers or objects stored behind the seat, increasing the potential for damage to the retractor either during normal use or in the event of a collision. Furthermore, the orientation of the retractor is often critical to its proper operation. Accordingly, it must be securely anchored such that its orientation is maintained both during normal use and in the event of a collision. There is a need for a way to protect the seat belt retractor from damage due to contact with passengers or objects behind the seat. There is a further need to maintain the orientation of the retractor to better ensure its proper operation. 
   SUMMARY 
   An embodiment of the present invention is a seat belt emergency locking retractor mounting system. The system comprises a bracket and a plate that cooperate with seat cushion frame components of a vehicle seat to form an enclosed mounting environment for the retractor. The bracket and plate form three sidewalls of the enclosure, with a side member of the cushion frame forming a fourth sidewall. The retractor is mounted within the enclosure and is attached to the bracket. The components of an aspect of the disclosed invention are located generally below the reclining apparatus of the seat&#39;s seatback in order to allow for adjustment of the seatback. An embodiment of the present invention ensures that the orientation of the retractor is maintained under various operating conditions and that the retractor is securely anchored in all directions. An embodiment of the present invention additionally protects the retractor from contact with passengers and objects located behind the seat. 
   One aspect of the present invention is a seat belt retractor mounting system for a vehicle seat. The system includes a bracket having a first sidewall and a second sidewall. A generally planar plate is located generally parallel to and spaced apart from the first sidewall of the bracket. The plate is coupled to the second sidewall. In addition, at least one of the bracket and plate are secured to, and cooperate with, a seat cushion frame of the seat to surround and protect an emergency locking retractor mounted to the first sidewall. 
   Another aspect of the present invention is a method for mounting a seat belt retractor to a vehicle seat. The method comprises the steps of providing a bracket having a first sidewall and a second sidewall, and coupling a generally planar plate to the bracket such that the plate is generally parallel to and spaced apart from the first sidewall of the bracket. Additional steps include securing at least one of the bracket and plate to a seat cushion frame of the seat, and mounting an emergency locking retractor mounted to the first sidewall such that the retractor is generally surrounded by the bracket, plate and frame. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
     Further features of the inventive embodiments will become apparent to those skilled in the art to which the embodiments relate from reading the specification and claims with reference to the accompanying drawings, in which: 
       FIG. 1  shows the general arrangement of a seat belt retractor mounting system installed into a left-hand vehicle seat frame according to an embodiment of the present invention; 
       FIG. 2  provides details of the components of the seat belt retractor mounting system of  FIG. 1 ; 
       FIG. 3  depicts a bracket component of the seat belt retractor mounting system of  FIG. 1 ; 
       FIG. 4A  is a rear elevational view of a plate component of the seat belt retractor mounting system of  FIG. 1 ; 
       FIG. 4B  is a side elevational view of the plate of  FIG. 4A ; 
       FIG. 5  is a rear view of the seat belt retractor mounting system of  FIG. 1 ; 
       FIG. 6  shows details of a portion of a seat cushion frame according to an embodiment of the present invention; 
       FIG. 7  is a front view of the seat belt retractor mounting system of  FIG. 1 ; 
       FIG. 8  is a side view of the seat belt retractor mounting system of  FIG. 1 ; and 
       FIG. 9  shows an emergency locking retractor being mounted to a bracket of a retractor mounting system installed into a right-hand vehicle seat frame according to an embodiment of the present invention. 
   

   DETAILED DESCRIPTION 
   The general arrangement of a seat belt retractor mounting system  10  is shown in  FIGS. 1 and 2  according to an embodiment of the present invention. Retractor mounting system  10  generally comprises a bracket  16  and a plate  18 . Retractor mounting system  10  is attached to a side member of a seat cushion frame  12  of a vehicle seat  14 , as discussed in greater detail below. 
   With reference to  FIGS. 2 and 3 , bracket  16  includes a first sidewall  20  and a second sidewall  22 . Second sidewall  22  may further include a mounting flange  24 . Bracket  16  may be formed as a unitary piece from any suitable material compatible with other components of seat belt retractor mounting system  10  and the expected environment including, without limitation, metals such as steel, plastic, and composites, and may be fabricated using any conventional processes such as, without limitation, molding, stamping, casting and machining. Bracket  16  may also be finished by such processes as painting, plating and coating, or left unfinished. 
   With reference to  FIGS. 4A ,  4 B and  5 , plate  18  is generally rectangularly-shaped and planar. Plate  18  may include one or more mounting holes  26 ,  28  for attaching the plate to mounting system  10  in a manner detailed further below. Plate  18  may further include one or more channels  30  along its longitudinal axis. 
   Plate  18  may be formed as a unitary piece from any suitable material compatible with other components of seat belt retractor mounting system  10  and the expected environment including, without limitation, metals such as steel, plastic, and composites, and may be fabricated using any conventional processes such as, without limitation, molding, stamping, casting and machining. Plate  18  may also be finished by such processes as painting, plating and coating, or left unfinished. 
   With reference now to  FIGS. 1 through 9  in combination, seat belt retractor mounting system is assembled by locating bracket  16  and plate  18  at a side member  32  of seat cushion frame  12  such that the side member is positioned between the bracket and plate ( FIGS. 2 and 5 ). Plate  18  is oriented such that channels  30  engage corresponding support braces  34  of frame  12  ( FIGS. 4B and 5 ). Mounting openings  26 ,  36  and  38  ( FIGS. 3 ,  4 A,  6 ) in plate  18 , bracket  16  and frame side member  32  respectively are aligned, then fastened together with one or more fasteners  40  such as rivets, bolts, nuts and screws, at least a portion of the fastener extending through the aligned openings ( FIGS. 2 and 5 ). Bracket  16  may also be attached directly to plate  18  with one or more fasteners  42  such as rivets, bolts, nuts and screws, at least a portion of the fastener extending through opening  28  in the plate and a corresponding opening  44  in mounting flange  24  of the bracket ( FIGS. 2 and 5 ). Bracket  16  may be further secured to frame  12  by one or more weldments  46  between the bracket and a cross member  48  of the frame ( FIG. 2 ). 
   With reference to  FIGS. 7 and 9 , a seat belt emergency locking retractor  50  is installed into seat  14  by locating the retractor within the sidewalls formed by bracket  16 , plate  18  and frame side member  32  such that a tab  52  of the retractor engages a notch  54  of the bracket. A mounting opening  56  of retractor  50  is aligned with a corresponding opening  58  of bracket  16  and is attached with one or more fasteners  60  such as rivets, bolts, nuts and screws, at least a portion of the fastener extending through the aligned openings. Tab  52 , notch  54 , openings  56 ,  58  and fastener  60  cooperate to secure emergency locking retractor  50  at a predetermined orientation to ensure its proper operation, i.e., allowing a seat belt web  62  housed by the retractor to move slidably in and out of the retractor during normal conditions without binding, yet resist movement of the web in the event of a sudden deceleration of the vehicle. Once retractor  50  is oriented and secured seat belt web  62  may be routed through seat  14  as shown generally in  FIG. 1  for use by an occupant of the seat. 
   In operation, retractor  44  is maintained in a predetermined orientation for proper operation of the emergency locking mechanism of the retractor in the event of a sudden deceleration, while allowing web  62  to move slidably in and out of the retractor during normal operation. The rigid, boxlike construction of the sidewalls formed by bracket  16 , plate  18  and frame side member  32  protect retractor  50  from contact with passengers and objects located behind the seat. Retractor mounting system  10  is rigidly secured to cross member  48 , support braces  34  and frame side member  32 , is accordingly securely anchored in all directions, and resists undesirable changes in the position or orientation of retractor  50  in the event of a vehicle collision. Furthermore, as can be seen in  FIG. 1 , the components of retractor mounting system  10  are located generally below a seat reclining apparatus  64  in order to allow normal seat adjustability and operation, such as changing the angular position of a seatback  66  of seat  14  without adversely affecting the orientation of retractor  50 . Retractor mounting system  10  also acts as a barrier between retractor  50  and other components of seat  14 , thereby preventing heat generated by the retractor from directly contacting the other components. 
   It should be noted that the sizes and shapes of the components of retractor mounting system  10  are not critical and may be varied to accommodate the needs of a particular seat frame  12  and emergency locking retractor  50 . For example, cutouts and openings may be installed in the bracket and/or plate to accommodate the various components of seat  14 . Likewise, stiffening elements such as ribs  68  ( FIGS. 3 and 4A ) may be incorporated into bracket  16  and/or plate  18  for added structural strength. 
   In some embodiments of the present invention seat cushion frame  12  may optionally include a reinforcing brace  70  coupled to the frame, as shown in  FIG. 9 . Brace  70  is coupled between cross member  48  and one or more frame support braces  34 , and acts to resist deformation or movement of the cross member and the support brace, thereby further aiding to resist undesirable changes in the position or orientation of retractor  50  in the event of a vehicle collision. Brace  70  may be coupled to cross member  48  and support brace  34  in any conventional manner using fasteners and/or weldments similar to fasteners  40  and weldments  46 , previously detailed above. 
   Brace  70  may be formed as a unitary piece from any suitable material compatible with other components of seat belt retractor mounting system  10  and the expected environment including, without limitation, metals such as steel, plastic, and composites, and may be fabricated using any conventional processes such as, without limitation, molding, stamping, casting and machining. Brace  70  may also be finished by such processes as painting, plating and coating, or left unfinished. 
   It should be noted that the figures variously depict embodiments of the present invention installed into seat frames  12  configured for installation into left and right sides of the vehicle interior. The disclosed embodiments of the present invention are generally located at the outboard edge of the seat frame. However, it is understood that the present invention may be likewise located at other positions along seat frame  12 , such as at an inboard edge, if dictated by the configuration of a particular safety restraint system. 
   While this invention has been shown and described with respect to a detailed embodiment thereof, it will be understood by those skilled in the art that changes in form and detail thereof may be made without departing from the scope of the claims of the invention. For example, the various features of the components of retractor mounting system  10 , seat  14  and retractor  44  may be keyed, indexed or rendered in separate mirror-image components for use in one of left- and right-hand seats in a vehicle. Alternatively, such left- and right-hand features may be incorporated into reconfigurable components having features compatible with installation of mounting system  10  into both left- and right-hand seats.