Seat belt latch plate assembly with secondary noise cancellation bumper

Abstract

A seat belt latch plate assembly includes a latch plate and a latch plate cover carried on the latch plate. The latch plate cover is made by a two-stage injection molding process and includes an integral bumper made of a soft, sound deadening material and having an energy absorbing cross-sectional shape.

Description

TECHNICAL FIELD

[0001] The present disclosure relates generally to the field of motor vehicle equipment, and more specifically to a new and improved seat belt buckle assembly that reduces the noise that would otherwise be generated by the assembly when unlocked and resting between the side of the vehicle seat and the B-pillar of the motor vehicle. BACKGROUND

[0002] When the current passenger seat belt is not in use, the buckle assembly connected to the seat belt webbing rests in a narrow area between the B-pillar trim and the side of the vehicle seat, with the buckle resting on the exposed seat belt webbing toward the vehicle seat. This resting position keeps the seat belt buckle assembly in an accessible position so that the passenger can easily find and grasp it when donning the seat belt.

[0003] However, it should be appreciated that when the seat belt buckle assembly is in this position, the mass of the seat belt buckle assembly can cause significant side-to-side motion when the vehicle is traveling over bumpy or uneven road surfaces. This can result in repeated impacts with the side of the vehicle seat, which in turn generates undesirable noise or clicking that can annoy or upset the motor vehicle operator or other passengers.

[0004] The present disclosure relates to a new and improved seat belt buckle assembly with integral bumpers that addresses and resolves this problem in an effective and efficient manner. The bumpers are an effective passive countermeasure that performs the required function without requiring any specific action by the operator.

[0005] Better noise reduction is ensured by the softness, thickness, number, location, and shape of the bumpers that absorb and dissipate impact energy over a wide range of contact severity and angles that would otherwise result in noise generation. The integral in situ formed bumpers have a purposeful appearance, while the soft material can be color keyed into the base plastic of the buckle cover to provide a superior overall perception of quality and design.

[0006] Advantageously, the integral bumpers provide long-term durability when attached to the seat belt buckle assembly by a two-stage injection molding process. As a result, the bumpers do not flake or delaminate due to use or age. SUMMARY

[0007] In accordance with the purposes and benefits described herein, a new and improved seat belt buckle assembly is provided. The seat belt buckle assembly includes a buckle and a buckle cover carried on the buckle. The buckle cover includes a first integral bumper made of a noise-dissipating material.

[0008] The first integral bumper can have a C-shaped cross-section. The first integral bumper can be a semi-ellipsoidal shape. The first integral bumper can include a first wall defining a first open channel. The first integral bumper can include a first lip and a second lip. The first wall can taper toward the first lip and the second lip.

[0009] The lock plate cover can be a two-stage one-piece plastic overmold on the lock plate. In one possible alternative embodiment, the lock plate cover can include a base portion overmold on the lock plate and a two-stage snap-on trim cover secured to the base portion.

[0010] The seat belt lock plate assembly can further include a second integral bumper spaced apart from the first integral bumper. In such embodiments, both the first and second integral bumpers can be semi-ellipsoidal shapes.

[0011] The first integral bumper can include a first wall defining a first open channel. The second integral bumper can include a second wall defining a second open channel. The first wall can include a first lip and a second lip. The second wall can include a third lip and a fourth lip. The first wall can taper toward the first lip and the second lip. The second wall can taper toward the third lip and the fourth lip.

[0012] The lock plate cover can include a two-stage one-piece overmold on the lock plate. The two-stage one-piece overmold can include (a) a body portion overmolded from a first material and (b) the first and second integral bumpers overmolded from a second material. The first material is harder than the second material, and the second material is softer than the first material. The first material can be selected from a first group of materials including nylon (polyamide), polypropylene, and combinations thereof. The second material can be selected from a second group of materials including thermoplastic elastomers.

[0013] In another possible embodiment, the lock plate cover includes a two-stage snap-on trim cover and a mating base portion overmold on the lock plate. The two-stage snap-on trim cover can include (a) a body portion overmolded from a first material and (b) the first and second integral bumpers overmolded from a second material. The first material is harder than the second material, and the second material is softer than the first material. The first material can be selected from a first group of materials including nylon (polyamide), polypropylene, and combinations thereof. The second material can be selected from a second group of materials including thermoplastic elastomers.

[0014] According to the present invention, there is provided a seat belt lock plate assembly, comprising:

[0015] a lock plate; and

[0016] a lock plate cover carried on the lock plate, the lock plate cover including a first integral bumper made of a noise-eliminating material.

[0017] According to one embodiment of the present invention, the first integral bumper has an energy absorbing C-shaped cross-section.

[0018] According to one embodiment of the present invention, the first integral bumper is semi-elliptical in shape.

[0019] According to one embodiment of the present invention, the first integral bumper includes a first wall defining a first open channel.

[0020] According to one embodiment of the present invention, the first wall includes a first lip and a second lip.

[0021] According to one embodiment of the present invention, the first wall tapers in thickness toward the first lip and the second lip.

[0022] According to one embodiment of the present invention, the lock plate cover is a two-stage single-piece plastic overmold on the lock plate.

[0023] According to one embodiment of the present invention, the lock plate cover is a two-stage snap-on trim cover and mating base portion overmold on the lock plate.

[0024] According to one embodiment of the present invention, the assembly further includes a second integral bumper spaced apart from the first integral bumper.

[0025] According to one embodiment of the present invention, both the first integral bumper and the second integral bumper are semi-elliptical in shape.

[0026] According to one embodiment of the present invention, the first integral bumper includes a first wall defining a first open channel, and the second integral bumper includes a second wall defining a second open channel.

[0027] According to one embodiment of the present invention, the first wall includes a first lip and a second lip, and the second wall includes a third lip and a fourth lip.

[0028] According to one embodiment of the present invention, the first wall tapers in thickness toward the first lip and the second lip, and the second wall tapers in thickness toward the third lip and the fourth lip.

[0029] According to one embodiment of the present invention, the lock plate cover is a two-stage single-piece overmold on the lock plate.

[0030] According to one embodiment of the present invention, the two-stage single-piece plastic overmold includes (a) a main portion molded from a first material and (b) the first integral bumper and the second integral bumper molded from a second material, wherein the first material is harder than the second material, and the second material is softer than the first material.

[0031] According to one embodiment of the present application, wherein the first material is selected from a first group of materials including nylon (polyamide), polypropylene, and combinations thereof, and the second material is selected from a second group of materials including thermoplastic elastomers.

[0032] According to one embodiment of the present application, wherein the lock plate cover is a two-stage snap-on trim cover and mating base portion overmold on the lock plate.

[0033] According to one embodiment of the present application, wherein the two-stage snap-on trim cover includes (a) a main body portion molded from a first material and (b) a first integral bumper and a second integral bumper molded from a second material, wherein the first material is harder than the second material, and the second material is softer than the first material.

[0034] According to one embodiment of the present application, wherein the first material is selected from a first group of materials including nylon (polyamide), polypropylene, and combinations thereof, and the second material is selected from a second group of materials including thermoplastic elastomers and combinations thereof.

[0035] In the following description, several preferred embodiments of a seat belt lock plate assembly are shown and described. As should be appreciated, the seat belt lock plate assembly can have other different embodiments, and various details thereof can be varied considerably without departing from the scope of the seat belt lock plate assembly as described below and in the claims that follow. Accordingly, the drawings and descriptions should be regarded as illustrative in nature and not restrictive. BRIEF DESCRIPTION OF DRAWINGS

[0036] The accompanying drawings incorporated herein and forming a part of the specification, illustrate several aspects of the seat belt lock plate assembly and, together with the description, serve to explain certain principles of the seat belt lock plate assembly.

[0037] Figure 1a is a perspective view of a new and improved seat belt lock plate assembly carried on a portion of a seat belt webbing;

[0038] Figure 1b is Figure 1a is a perspective view of a lock plate of the seat belt lock plate assembly shown in

[0039] Figure 2 and Figure 3 are, respectively, a detailed side view and a top view of the seat belt lock plate assembly shown in Fig. 1, showing how the integral bumpers on the lock plate cover function to prevent the lock plate from engaging the side of the vehicle seat to eliminate the noise that would otherwise be generated;

[0040] Figure 4is an additional top plan view showing how the spaced apart dampers act uniformly to eliminate noise when the seat belt lock plate assembly has rotated relative to the side of the vehicle seat;

[0041] Figure 5 is a schematic cross-sectional view through the middle of the first damper;

[0042] Figure 6 is a view similar to Figure 5 but showing the first damper after initial contact with the vehicle seat;

[0043] Figure 7 is a schematic cross-sectional view through the middle of the second damper;

[0044] Figure 8 is a view similar to Figure 7 but showing the second damper after initial contact with the vehicle seat;

[0045] Figure 9 is a cross-sectional view of one possible embodiment of the seat belt lock plate assembly in which the lock plate cover is a two-stage overmold on the lock plate;

[0046] Figure 10 is a perspective view of an alternate embodiment of the seat belt lock plate assembly in which the lock plate cover is a two-piece construction and includes a base portion overmold on the lock plate and a mating two-stage snap-on trim cover secured to the base portion by suitable fastening means.

[0047] Reference will now be made in detail to the presently preferred embodiments of the seat belt lock plate assembly, examples of which are illustrated in the accompanying drawings. DETAILED DESCRIPTION

[0048] Reference is now made to FIGS. 1-8 which show a new and improved seat belt lock plate assembly 10. The seat belt lock plate assembly 10 includes a lock plate 12 made of steel, metal or other high strength material and a lock plate cover 14 carried on the lock plate.

[0049] The lock plate 12 includes a tongue 16 having a locking lug 18 with a central opening 20. As is known in the art, the locking lug 18 is received and secured in a latch element (not shown) of a seat belt buckle. The tongue 16 also includes a guide slot 22 which receives a seat belt webbing 24 which carries the seat belt lock plate assembly 10.

[0050] The lock plate cover 14 includes a first integral damper 26 and a second integral damper 28 spaced apart from the first integral damper. Both dampers 26, 28 act to dampen the rotational movement of the lock plate 12 when the seat belt lock plate assembly 10 engages, for example, Figure 2 , Figure 3 andFigure 4 The side of the vehicle seat 30 shown is made of a noise-eliminating material. For purposes of this document, a noise-eliminating material is defined as a thermoplastic elastomer.

[0051] In the embodiment shown in FIGS. 1-5, the lock plate cover 14 includes a main body portion 32 that is molded from a plastic material, while the first and second integral bumpers 26, 28 of the lock plate cover are molded from an elastomeric material. The plastic material is harder than the elastomeric material, and the elastomeric material is softer than the plastic material.

[0052] The bumpers 26, 28 can take on a variety of different shapes. As best shown in FIG. 1, each of the bumpers 26, 28 can be semi-ellipsoidal in shape. As best shown in FIG. 2, each of the bumpers 26, 28 can be semi-elliptical in shape. Figure 5 and 6 As best shown in FIG. 1, the first integral bumper 26 includes a first wall 34 having a first lip 36 and a second lip 38 that delineate a first open channel 40 defined by the first wall. In addition, the first wall 34 tapers in thickness toward the first and second lips 36, 38. Similarly, as best shown in FIG. 2, the second integral bumper 28 includes a second wall 42 having a third lip 44 and a fourth lip 46 that delineate a second open channel 48 defined by the second wall. In addition, the second wall 42 tapers in thickness toward the third and fourth lips 44, 46. Figure 7 and 8 As best shown in FIG. 1, the first integral bumper 26 includes a first wall 34 having a first lip 36 and a second lip 38 that delineate a first open channel 40 defined by the first wall. In addition, the first wall 34 tapers in thickness toward the first and second lips 36, 38. Similarly, as best shown in FIG. 2, the second integral bumper 28 includes a second wall 42 having a third lip 44 and a fourth lip 46 that delineate a second open channel 48 defined by the second wall. In addition, the second wall 42 tapers in thickness toward the third and fourth lips 44, 46. Figure 5 and 7 As best shown in FIG. 1, the first integral bumper 26 includes a first wall 34 having a first lip 36 and a second lip 38 that delineate a first open channel 40 defined by the first wall. In addition, the first wall 34 tapers in thickness toward the first and second lips 36, 38. Similarly, as best shown in FIG. 2, the second integral bumper 28 includes a second wall 42 having a third lip 44 and a fourth lip 46 that delineate a second open channel 48 defined by the second wall. In addition, the second wall 42 tapers in thickness toward the third and fourth lips 44, 46.

[0053] The hollow cross-section, tapered wall thickness (thicker at the base, thinner at the lips 36, 38), and curved shape of the bumpers 26, 28 help to define the operating characteristics of the bumpers. The bumpers 26, 28 are initially highly flexible to absorb the energy created by the impact of the lock plate assembly 10 with the vehicle seat 30. The flexibility is gradually reduced to decelerate the lock plate assembly 10 (see FIG. 3) after the initial contact and prevent further portions from contacting the vehicle seat 30. Figure 6 and 8

[0054] The elastomeric material from which the bumpers 26, 28 are constructed is soft enough to maintain sufficient flexibility and durability to resist warping or degradation in a typical vehicle environment. The elastomeric material is also compatible with the plastic material so that the lock plate cover 14 can be over-molded by a two-stage molding process known in the art. In at least some embodiments, the first and second integral bumpers 26, 28 will also be color-matched to the main body portion 32.

[0055] ​The main body 32 of the locking plate cover 14 may be made of a plastic material selected from a first group of materials, including nylon (polyamide), polypropylene, and combinations thereof. The first and second buffers 26, 28 may be made of an elastomeric material selected from a second group of materials, including thermoplastic elastomers. It should be understood here that the materials listed are merely examples of those that may be used and should not be considered as a limitation on the scope.

[0056] It should be understood that the dimensions, number, and external shape of the integral buffers 26, 28 on the locking plate cover 14 can vary to provide the desired performance and eliminate clicking and noise when the locking plate assembly 10 is disengaged and rests between the side of the vehicle seat 30 and the B-pillar of the motor vehicle. The height of the buffers 26, 28 should prevent all parts of the locking plate 12 from contacting the vehicle seat 30 when disengaged. The number and external shape of the buffers 26, 28 can best be determined by the shape of the surface of the vehicle seat 30 in contact with the locking plate assembly 10 and the dimensional stability of the buffers or secondary material.

[0057] like Figure 9 As shown, in one possible embodiment, the locking plate cover 14 may include a secondary single-piece plastic overmolded part on the locking plate 12.

[0058] like Figure 10 As shown, in an alternative embodiment, the locking plate cover 14 may include a secondary engagement decorative cover 50 and a mating base portion overmolding 52 on the locking plate 12. The secondary engagement decorative cover 50 may be secured to the base portion overmolding 52 by any suitable fastening means, such as a mating pin 54 on the cover and a pin receiver 56 on the base portion overmolding.

[0059] The foregoing has been presented for purposes of illustration and description. It is not intended to be exhaustive or to limit the embodiments to the exact forms disclosed. Significant modifications and variations can be made in accordance with the foregoing teachings. For example, it should be understood that the locking plate cover 14 may take other configurations. For example, one or more integral buffers may be provided on opposite sides or faces of the locking plate cover 14 to prevent clicking against the sides or pillars of the motor vehicle. All such modifications and variations are within the scope of the appended claims when interpreted according to their fair, legal, and equally enjoyable scope.

Claims

1. A seat belt buckle assembly comprising: a buckle; and a buckle cover carried on the buckle, the buckle cover comprising a first integral bumper made of a noise dampening material, wherein the first integral bumper is semi-ellipsoidal in shape and comprises a first wall defining a first open channel, the first integral bumper being initially highly flexible upon initial contact with a vehicle seat to dampen energy created by the seat belt buckle assembly impacting the vehicle seat, the flexibility gradually decreasing to decelerate the seat belt buckle assembly and prevent further portions from contacting the vehicle seat after the initial contact.

2. The seat belt buckle assembly of claim 1, wherein the first integral bumper has an energy absorbing C-shaped cross-section.

3. The seat belt buckle assembly of claim 1, wherein the first integral bumper has a hollow cross-section, a gradually thinning wall thickness, and a curved shape.

4. The seat belt buckle assembly of claim 1, wherein the first wall comprises a first lip and a second lip.

5. The seat belt buckle assembly of claim 4, wherein the first wall gradually thins toward the first lip and the second lip.

6. The seat belt buckle assembly of claim 5, wherein the buckle cover is a two-stage, one-piece plastic overmold on the buckle.

7. The seat belt buckle assembly of claim 5, wherein the buckle cover is a two-stage snap-in trim cover and mating base portion overmold on the buckle.

8. The seat belt buckle assembly of claim 1, further comprising a second integral bumper spaced apart from the first integral bumper.

9. The seat belt buckle assembly of claim 8, wherein the first integral bumper and the second integral bumper are both semi-ellipsoidal in shape.

10. The seat belt buckle assembly of claim 9, wherein the first integral bumper comprises a first wall defining a first open channel and the second integral bumper comprises a second wall defining a second open channel.

11. The seat belt buckle assembly of claim 10, wherein the first wall comprises a first lip and a second lip and the second wall comprises a third lip and a fourth lip.

12. The seat belt buckle assembly of claim 11, wherein the first wall gradually thins toward the first lip and the second lip and the second wall gradually thins toward the third lip and the fourth lip, the buckle cover being a two-stage, one-piece plastic overmold on the buckle, the two-stage, one-piece plastic overmold comprising a main portion molded from a first material and the first integral bumper and the second integral bumper molded from a second material, wherein the first material is harder than the second material and the second material is softer than the first material.

13. The seat belt lock plate assembly of claim 11, wherein the lock plate cover is a two-stage snap-on trim cover and mating base portion overmold.

14. The seat belt lock plate assembly of claim 13, wherein the two-stage snap-on trim cover includes a main body portion formed of a first material and the first integral bumper and the second integral bumper formed of a second material, wherein the first material is harder than the second material and the second material is softer than the first material.

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