Energy-absorbing safety belt assembly

Abstract

An energy absorbing seatbelt assembly according to various embodiments includes a frame body, a first reel portion, and a separately formed second reel portion, where both reel portions are rotatably coupled to the frame body. The torsion bar includes a first end coupled to the first spool portion and a second end coupled to the second spool portion, where both ends of the torsion bar rotate in opposite directions when the first and second spool portions rotate relative to the frame body. The energy absorbing safety belt assembly also includes a cable having a first end coupled to the first spool portion, a second end coupled to the second spool portion, and an intermediate portion coupled to the safety belt buckle or anchor, the intermediate portion of the cable extending between the first end of the cable and the second end of the cable.

Description

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[0002] This application claims the benefit of U.S. Provisional Patent Application No. 63 / 424,287, filed November 10, 2022, the entire contents of which are incorporated herein by reference. Technical Field

[0003] The present invention relates to safety devices for passenger vehicles. In particular, the present invention relates to energy-absorbing seat belt assemblies. Passenger vehicles may include, for example, automobiles, ships, trains, airplanes, and spacecraft. Background Art

[0004] Most energy-absorbing seatbelt assemblies, such as seatbelt retractors, are associated with the portion of the seatbelt webbing that extends across the vehicle occupant's chest and shoulders. By absorbing energy throughout a vehicle emergency, the occupant is gradually decelerated, thereby absorbing the high forces experienced during a vehicle emergency in the safest and most efficient manner. However, some vehicles may require energy absorption associated with the portion of the seatbelt webbing that extends across the occupant's legs. Such energy-absorbing seatbelt assemblies may be incorporated into a seatbelt buckle assembly or a seatbelt anchor assembly.

[0005] In conventional energy-absorbing buckle assemblies, for example, a torsion bar is directly or indirectly fixedly coupled to a frame at one end and to a rotating spool at the other end. The buckle is coupled to the spool via a cable, and during a vehicle emergency, due to occupant movement, a rotational force is applied to the spool when the buckle is tensioned. When a vehicle emergency is detected, the end of the torsion bar fixedly coupled to the frame will remain fixed in place, while the end of the torsion bar coupled to the spool will rotate with the spool. The torsion bar will thus bend and absorb energy. However, by securing one end of the torsion bar to the frame, significant forces are applied to the frame, necessitating the use of thicker, stronger materials. Therefore, there is a need for an energy-absorbing seatbelt assembly for a seatbelt leg portion that can efficiently absorb energy during a vehicle emergency while minimizing or eliminating forces applied to the assembly frame. Summary of the Invention

[0006] Various embodiments include an energy-absorbing seatbelt assembly for a vehicle. The assembly includes a frame, a first reel portion rotatably coupled to the frame, and a second reel portion also rotatably coupled to the frame. The second reel portion and the first reel portion are formed separately. A torsion bar is disposed within the first reel portion and the second reel portion, with a first end coupled to the first reel portion and a second end coupled to the second reel portion. During a vehicle emergency, the first reel portion rotates in a first direction relative to the frame, and the second reel portion rotates in a second direction relative to the frame, the second direction being opposite to the first direction.

[0007] In other embodiments, an energy absorbing seat belt assembly for a vehicle includes a buckle and a frame. A first reel portion is rotatably coupled to the frame, and a second reel portion is also rotatably coupled to the frame. The second reel portion and the first reel portion are formed separately. A torsion bar is disposed within the first reel portion and the second reel portion, with a first end coupled to the first reel portion and a second end coupled to the second reel portion. The system further includes a cable having a first end coupled to the first reel portion, a second end coupled to the second reel portion, and a middle portion coupled to the buckle, wherein the middle portion of the cable extends between the first end of the cable and the second end of the cable. During a vehicle emergency, the cable is tensioned such that the first reel portion rotates in a first direction relative to the frame and the second reel portion rotates in a second direction relative to the frame, the second direction being opposite to the first direction.

[0008] In other embodiments, an energy absorbing seat belt assembly for a vehicle includes a frame, a first reel portion rotatably coupled to the frame, and a second reel portion also rotatably coupled to the frame. The second reel portion and the first reel portion are formed separately. A torsion bar is disposed within the first reel portion and the second reel portion, with a first end coupled to the first reel portion and a second end coupled to the second reel portion. The first reel portion includes a reel extension, and the second reel portion includes a reel cavity, wherein the reel extension extends into the reel cavity and the second reel portion is rotatable about the reel extension. During a vehicle emergency, the first reel portion rotates in a first direction relative to the frame and the second reel portion, and the second reel portion rotates in a second direction relative to the frame and the first reel portion, the second direction being opposite to the first direction. BRIEF DESCRIPTION OF THE DRAWINGS

[0009] The drawings illustrate only exemplary structures and certain features, which may be used alone or in combination with other features. The present invention should not be limited to the embodiments shown.

[0010] Figure 1A is a perspective view of an embodiment of an energy-absorbing seat belt assembly before an emergency situation.

[0011] Figure 1B is a perspective view of the energy-absorbing seat belt assembly of FIG. 1 after an emergency situation.

[0012] Figure 2A yes Figure 1A A cross-sectional view of an energy-absorbing seat belt assembly.

[0013] Figure 2B yes Figure 1B A cross-sectional view of an energy-absorbing seat belt assembly.

[0014] Figure 3A yes Figure 1A A perspective view of an energy absorbing seat belt assembly showing the first spool portion but not the second spool portion.

[0015] Figure 3B yes Figure 1A A perspective view of an energy absorbing seat belt assembly showing the second spool portion but not the first spool portion.

[0016] Figures 4A-4B yes Figure 3A A perspective view of the first scroll portion.

[0017] Figures 5A-5B yes Figure 3B A perspective view of the second scroll portion.

[0018] Figures 6A-6B This is a perspective view of the cable.

[0019] Figure 7A yes Figures 4A-4B A cross-sectional view of the first scroll portion.

[0020] Figure 7B yes Figure 7A A cross-sectional view of the first reel portion and the cable.

[0021] Figure 8A yes Figures 5A-5B A cross-sectional view of the second scroll portion.

[0022] Figure 8B yes Figure 8A A cross-sectional view of the second reel portion and the cable.

[0023] Figure 9A yes Figures 4A-4B A perspective view of the first spool portion showing the torsion bar cavity.

[0024] Figure 9B yes Figures 5A-4B A perspective view of the second spool portion showing the torsion bar cavity.

[0025] Figure 9C yes Figure 9A The first scroll part, Figure 9B Exploded view of the second spool portion and the torsion bar.

[0026] Figure 10A yes Figure 9A An exploded view of the first reel portion, the frame body and the first sleeve.

[0027] Figure 10B yes Figure 9B An exploded view of the second reel portion, the frame body and the second sleeve.

[0028] Figure 11A yes Figure 1A A perspective view of an energy-absorbing seat belt assembly with a buckle.

[0029] Figure 11B yes Figure 1B A perspective view of an energy-absorbing seat belt assembly with a buckle.

[0030] Figure 11C yes Figure 11A A cross-sectional view of a portion of an energy-absorbing seat belt assembly.

[0031] Figure 12 yes Figure 1B A perspective view of an energy-absorbing seat belt assembly having an anchor.

[0032] Figure 13A yes Figure 1A A view of the multiple energy absorbing steps during operation of an energy absorbing seat belt assembly.

[0033] Figure 13B yes Figure 1A The energy absorption diagram of the energy absorbing seat belt assembly during operation shows Figure 13A Multiple steps. DETAILED DESCRIPTION

[0034] The present invention relates to passenger vehicle safety devices. The devices, assemblies, systems, and methods disclosed herein provide an energy-absorbing seatbelt assembly comprising a two-piece reel system in which two reel sections rotate in opposite directions during a vehicle emergency. In one example, the energy-absorbing seatbelt assembly is used in a rear-seat vehicle application. During a vehicle emergency, the legs of the seatbelt, coupled to a buckle or anchor, are tensioned by the occupant's body movement. This causes the buckle or anchor to tension the cables coupled to the two reel sections, causing the reel sections to rotate in opposite directions relative to each other. Consequently, a torsion bar coupled to the two reel sections twists to absorb energy. By using counter-rotating reel sections, there is no need to lock one end of the torsion bar to the frame of the energy-absorbing seatbelt assembly, thereby allowing for greater flexibility in the choice of frame material. In other examples, the assembly can be used in other passenger vehicles, such as, but not limited to, ships, trains, airplanes, and spacecraft. As non-limiting examples, vehicle emergencies can include traffic accidents, rapid deceleration due to sudden braking, or other high-g-load events such as high-speed cornering.

[0035] As shown, one embodiment of an energy-absorbing seat belt assembly 100 for a vehicle includes a frame 10 having a first arm 11, a second arm 14, and a base 17. A first spool portion 20 is rotatably coupled to the frame 10 via a mounting extension 27 extending into a first aperture 12 defined by the first arm 11. A second spool portion 30 is rotatably coupled to the frame 10 via a mounting extension 37 extending into a second aperture 15 defined by the second arm 14. A first sleeve 60 is disposed within the first aperture 12 between the inner surface 13 of the first aperture 12 and the mounting extension 27. A second sleeve 61 is disposed within the second aperture 15 between the inner surface 16 of the second aperture 15 and the mounting extension 37. The first and second sleeves 60, 61 allow the first and second spool portions 20, 30 to rotate freely relative to the frame 10 with minimal friction. The first and second sleeves 60, 61 are formed from acetal. In other embodiments, the first and second sleeves may be formed from polytetrafluoroethylene (PTFE), nylon, or other plastic materials. In some embodiments, the first sleeve 60 and the second sleeve 61 may be coated with a low friction material to ensure smooth rotation, such as molybdenum disulfide or PTFE.

[0036] When rotatably coupled to the frame body 10, the first reel portion 20 and the second reel portion 30 are also rotatably coupled to each other. The first reel portion 20 includes a reel extension 21, and the second reel portion 30 defines a reel cavity 31. Figure 2A As shown, when mounting extensions 27 and 37 are disposed within first and second apertures 12 and 15, respectively, reel extension 21 of first reel portion 20 is disposed within reel cavity 31 of second reel portion 30, thereby allowing second reel portion 30 to rotate about reel extension 21. This arrangement allows each of first and second reel portions 20, 30 to freely rotate relative to one another. In some embodiments, reel extension 21 may be coated with a low-friction material, such as molybdenum disulfide or PTFE, to ensure smooth rotation. In other embodiments, a sleeve may be disposed around the reel extension to ensure smooth rotation.

[0037] In order to perform an energy absorption function during a vehicle emergency, a torsion bar 40 is provided within the first and second reel portions 20 and 30. The torsion bar 40 includes a first end 41 and a second end 42. The first end 41 is provided within the torsion bar cavity 26 defined by the first reel portion 20. Figure 9A The second end 42 is disposed in the torsion bar cavity 36 defined by the second reel portion 30, as shown. Figure 9BAs shown. The first end 41 and the second end 42 include non-circular shapes that match the non-circular shapes of the torsion bar cavity 26 and the torsion bar cavity 36. The matching interlocking shapes of the first end 41 and the torsion bar cavity 26, and the second end 42 and the torsion bar cavity 36, ensure that the first end 41 is connected to the first reel portion 20 and the second end 42 is connected to the second reel portion 30. Therefore, when the first reel portion 20 and the second reel portion 30 rotate relative to each other, the first end 41 and the second end 42 will rotate relative to each other in the same manner. As shown, the non-circular shape is a hexagonal shape. In other embodiments, the non-circular shape can be any other type of non-circular shape, including a triangle, a square, or an octagon, so that the first end of the torsion bar and the second end of the torsion bar can be locked so that they cannot rotate relative to the first reel portion and the second reel portion, respectively. The torsion bar 40 can be formed from high elongation steel. In other embodiments, the specific material and strength of the torsion bar can be selected based on the requirements of a specific vehicle.

[0038] To rotate during a vehicle emergency, the first and second reel portions 20 and 30 are coupled to a cable 50. A first end 51 of the cable 50 is coupled to the first reel portion 20. A second end 55 of the cable 50 is coupled to the second reel portion 30. Figures 11A-11C As shown, the intermediate portion 59 of the cable 50 is coupled to the buckle 70. The base 17 of the frame 10 defines a third hole 18 for securing the frame 10 to the vehicle via a fastener. Thus, when the leg of the seat belt is coupled to the buckle 70 and a vehicle emergency occurs, the occupant's body movement will cause the seat belt to tighten and pull the buckle 70 away from the frame 10, thereby tightening the cable 50. In other embodiments, the intermediate portion 59 of the cable 50 is coupled to the seat belt anchor 71, such as Figure 12 shown.

[0039] When the cable 50 is tensioned away from the frame 10, the first end 51 of the cable 50 causes the first reel portion 20 to rotate in the first rotation direction A, as shown in FIG. Figure 1A Similarly, the second end 55 of the cable 50 rotates the second reel portion 30 in a second rotational direction B opposite to the first rotational direction A. The rotation of the first reel portion 20 and the second reel portion 30 is due to the tangential force T applied to the first reel portion 20 and the second reel portion 30 by the cable 50, as shown in FIG. Figure 7B and 8B shown. Figure 1A and 2A The energy absorbing seat belt assembly 100 is shown before an emergency situation. Figure 1B and 2B The assembly 100 is shown after an emergency situation. Figure 2A As can be seen from FIG, the first reel portion 20 and the second reel portion 30 have not yet started to rotate in the rotation directions A and B, respectively. Thus, the torsion bar 40 is in a non-twisted state. Figure 2BAs can be seen in FIG, the first and second reel portions 20 and 30 have fully rotated in the respective rotational directions A and B. As a result, the torsion bar 40 twists, thereby absorbing energy from the occupant's body movement.

[0040] Now refer to Figures 4A-8B The first reel portion 20 defines a through hole 22. The through hole 22 includes a first diameter 23 and a second diameter 24, wherein the second diameter 24 is larger than the first diameter 23. The first reel portion 20 further defines a cable ramp 28. Figure 7B As shown, the cable 50 is wound around the first spool portion 20 and passes through the through hole 22. When the energy absorbing safety belt assembly 100 is in an emergency situation, a portion of the cable 50 is located on the cable ramp 28. The first terminal 52 is crimped or otherwise attached to the cable 50, adjacent to the first end 51 of the cable 50, and is disposed within the through hole 22. The first terminal 52 includes Figure 6A The outer diameter 53 is shown to be larger than the first diameter 23 and smaller than the second diameter 24. Therefore, during a vehicle emergency, when the cable 50 is tensioned by movement of a vehicle occupant, the end face 54 of the first terminal 52 will abut the shoulder 25 of the first spool portion 20. Specifically, when the cable 50 is tensioned, the cable 50 applies a tangential force T to the first spool portion 20, wherein the cable ramp 28 and the shoulder 25 help to allow the cable 50 to apply a torque to the first spool portion 20, so that the first spool portion 20 rotates smoothly in the first rotational direction A.

[0041] Similarly, the second reel portion 30 defines a through hole 32. The through hole 32 includes a first diameter 33 and a second diameter 34, wherein the second diameter 34 is larger than the first diameter 33. The second reel portion 30 also defines a cable ramp 38. Figure 8B As shown, the cable 50 is wound around the second spool portion 30 and passes through the through hole 32. When the energy absorbing safety belt assembly 100 is in the emergency state, a portion of the cable 50 is located on the cable ramp 38. The second terminal 56 is crimped or otherwise attached to the cable 50, adjacent to the second end 55 of the cable 50, and is disposed within the through hole 32. The second terminal 56 includes Figure 6A The outer diameter 57 is shown to be larger than the first diameter 33 and smaller than the second diameter 34. Therefore, during a vehicle emergency, when the cable 50 is tensioned by movement of a vehicle occupant, the end face 58 of the second terminal 56 will abut the shoulder 35 of the second spool portion 30. Specifically, when the cable 50 is tensioned, the cable 50 applies a tangential force T to the second spool portion 30, wherein the cable ramp 38 and the shoulder 35 help to allow the cable 50 to apply a torque to the second spool portion 30, so that the second spool portion 30 rotates smoothly in the second rotational direction B.

[0042] When the first reel portion 20 and the second reel portion 30 rotate in the rotation direction A and the rotation direction B respectively, Figure 1AThe emergency status shown rotates to Figure 1B After the emergency situation shown, the energy absorption curve (load) gradually increases during the last quarter turn. The initial tangential force T will transition to a linear force L during the last quarter turn, thereby reducing the moment M exerted by the cable 50 on the first reel portion 20 and the second reel portion 30, as shown in FIG. Figure 13A As shown, M0=M1>M2>M3>M4. Therefore, more energy is required to continue to twist the torsion bar 40. Therefore, during a vehicle emergency, at the last moment of energy absorption, more energy generated by the occupant's body movement is absorbed by twisting the torsion bar 40. Figure 13B An exemplary load diagram is shown, indicating Figure 13A The load is shown as a function of the rotational position of the second spool portion 30 throughout the rotation. As shown, during the last quarter of a turn, once the torque begins to transition to a maximum amount representing the peak load applied by an occupant during a vehicle emergency event, the load increases, depending on the severity of the event.

[0043] The description herein is for illustrative purposes and is not intended to be exhaustive or to limit the disclosed embodiments. It should be understood that various modifications and variations will be apparent to those skilled in the art and may be made without departing from the spirit and scope of the following claims. Therefore, other embodiments are within the scope of the claims. The described embodiments have been selected to best explain the principles of the energy-absorbing seat belt assembly and its practical applications, and to enable others skilled in the art to understand various embodiments of the assembly, with various modifications depending on the specific application contemplated.

[0044] As used herein, the terms "coupled," "connected," and the like refer to the joining of two components directly or indirectly to one another. Such joining may be fixed (e.g., permanent) or movable (e.g., removable or releasable). Such joining may be achieved by the two components, or the two components and any additional intermediate components, being integrally formed as a single unitary body, or by the two components, or the two components and any additional intermediate components, being attached to one another.

[0045] The terms used herein are for the purpose of describing specific embodiments only and are not intended to limit the present invention. As used herein, the singular forms "a" and "an" are intended to include the plural forms as well, unless the context clearly indicates otherwise. It should also be understood that when the term "comprising" is used in the specification, it specifies the presence of the features, operations, elements and / or components, but does not exclude the presence or addition of one or more other features, operations, elements, components and / or groups thereof.

Claims

1. An energy-absorbing safety belt assembly for a vehicle, comprising: frame; a first reel portion rotatably coupled to the frame body and a second reel portion rotatably coupled to the frame body, the second reel portion and the first reel portion being formed separately; as well as a torsion bar with a first end coupled to the first reel portion and a second end coupled to the second reel portion; During a vehicle emergency, the first reel portion rotates relative to the frame in a first direction, and the second reel portion rotates relative to the frame in a second direction, the second direction being opposite to the first direction. 2 . The energy absorbing seat belt assembly of claim 1 , further comprising a cable coupled to the first spool portion at a first end and to the second spool portion at a second end.

3. The energy absorbing seat belt assembly of claim 2, further comprising a buckle, wherein an intermediate portion of the cable is coupled to the buckle, the intermediate portion of the cable extending between the first end of the cable and the second end of the cable.

4. The energy-absorbing safety belt assembly according to claim 2, wherein: The first reel portion defines a through hole, and the second reel portion defines a through hole; and The through hole of the first reel portion includes a first diameter and a second diameter, and the through hole of the second reel portion includes a first diameter and a second diameter.

5. The energy-absorbing safety belt assembly according to claim 4, wherein: The first end of the cable passes through the through hole of the first reel portion, and the second end of the cable passes through the through hole of the second reel portion.

6. The energy-absorbing safety belt assembly according to claim 5, wherein: The cable further includes a first terminal coupled to the cable near the first end and a second terminal coupled to the cable near the second end, the first terminal having an outer diameter, and the second terminal having an outer diameter, the outer diameter of the first terminal being larger than the first diameter of the through hole of the first reel portion, and the outer diameter of the second terminal being larger than the first diameter of the through hole of the second reel portion.

7. The energy-absorbing safety belt assembly according to claim 6, wherein: The through hole of the first reel portion further includes a shoulder located between the first diameter of the through hole of the first reel portion and the second diameter of the through hole of the first reel portion, and The through hole of the second scroll portion further includes a shoulder portion located between the first diameter of the through hole of the second scroll portion and the second diameter of the through hole of the second scroll portion.

8. The energy-absorbing safety belt assembly according to claim 7, wherein: The first terminal includes an end surface, and the second terminal includes an end surface, and The end surface of the first terminal is adjacent to the shoulder of the first through hole, and the end surface of the second terminal is adjacent to the shoulder of the second through hole.

9. The energy-absorbing safety belt assembly according to claim 1, further comprising a first sleeve and a second sleeve, wherein: The first sleeve is disposed between the frame and the first reel portion, and wherein the second sleeve is disposed between the frame and the second reel portion.

10. The energy-absorbing safety belt assembly according to claim 9, wherein: The frame includes a first arm and a second arm, the first arm defining a first aperture, and the second arm defining a second aperture.

11. The energy-absorbing safety belt assembly according to claim 10, wherein: The first reel portion includes a mounting extension, and the second reel portion includes a mounting extension, and The mounting extension of the first reel portion passes through the first hole, and the mounting extension of the second reel portion passes through the second hole.

12. The energy-absorbing safety belt assembly according to claim 11, wherein: The first sleeve is disposed between an inner surface of the first aperture and the mounting extension of the first spool portion, and The second sleeve is disposed between an inner surface of the second hole and the mounting extension of the second reel portion.

13. The energy-absorbing safety belt assembly according to claim 10, wherein: The frame includes a base extending between the first arm and the second arm, and The base defines a third hole for mounting the frame to the vehicle using a fastener.

14. The energy-absorbing safety belt assembly according to claim 1, wherein: The first scroll portion includes an extension, and the second scroll portion includes a cavity, and The extending portion extends into the cavity, and the second scroll portion is rotatable around the extending portion.

15. The energy-absorbing safety belt assembly according to claim 1, wherein: The first end of the torsion bar includes a non-circular shape, and the second end of the torsion bar includes a non-circular shape.

16. The energy-absorbing safety belt assembly according to claim 15, wherein: The first spool portion includes a torsion bar cavity, and Wherein, the torsion bar cavity of the first reel portion comprises a non-circular shape matching the non-circular shape of the first end of the torsion bar.

17. The energy-absorbing safety belt assembly according to claim 16, wherein: The second spool portion includes a torsion bar cavity, and The torsion bar cavity of the second reel portion includes a non-circular shape that matches the non-circular shape of the second end of the torsion bar.

18. The energy-absorbing safety belt assembly according to claim 17, wherein: The first end of the torsion bar is disposed within the torsion bar cavity of the first spool portion, and the second end of the torsion bar is disposed within the torsion bar cavity of the second spool portion.

19. An energy-absorbing safety belt assembly for a vehicle, comprising: Buckle; frame; a first reel portion rotatably coupled to the frame body and a second reel portion rotatably coupled to the frame body, the second reel portion and the first reel portion being formed separately; a torsion bar with a first end coupled to the first reel portion and a second end coupled to the second reel portion; as well as a cable having a first end coupled to the first spool portion, a second end coupled to the second spool portion, and a middle portion coupled to the buckle, the middle portion of the cable extending between the first end of the cable and the second end of the cable; During a vehicle emergency, the cable is tensioned, causing the first spool portion to rotate relative to the frame in a first direction and the second spool portion to rotate relative to the frame in a second direction opposite to the first direction.

20. An energy-absorbing safety belt assembly for a vehicle, comprising: frame; a first reel portion rotatably coupled to the frame body and a second reel portion rotatably coupled to the frame body, the second reel portion and the first reel portion being formed separately; as well as a torsion bar with a first end coupled to the first reel portion and a second end coupled to the second reel portion; wherein the first spool portion includes a spool extension and the second spool portion includes a spool cavity, wherein the spool extension extends into the spool cavity and the second spool portion is rotatable about the spool extension; and During a vehicle emergency, the first reel portion rotates in a first direction relative to the frame and the second reel portion, and the second reel portion rotates in a second direction relative to the frame and the first reel portion, the second direction being opposite to the first direction.

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