FIELD OF THE INVENTION [0001] This invention relates to a seatbelt anchor assembly adapted for use as part of a motor vehicle seatbelt restraint assembly.

BACKGROUND OF THE INVENTION [0002] 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. [0003] 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. [0004] 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. [0005] 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. [0006] A seatbelt anchor assemblies in accordance with this invention provide the above-mentioned features of adaptability, ease of assembly, and structural integrity. [0007] 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.

BRIEF DESCRIPTION OF THE DRAWINGS

[0008] Figure 1 is a perspective view of a seatbelt anchor assembly in accordance with a first embodiment of this invention shown with the ferrule having a cable attachment end;

[0009] Figure 2 is a pictorial view of the anchor assembly in accordance with a second alternative embodiment of this invention in which the ferrule is connected with a strap for vehicle attachment;

[0010] Figure 3 is an exploded pictorial view of the components of the seatbelt anchor assembly shown in Figure 1 in an exploded unassembled condition; [0011] Figure 4 is a side view of the assembly shown in Figures 1 and 3 showing the mechanical connection between the anchor and ferrule components; [0012] Figure 5 is a front view of the assembly shown in Figures 1 and 3;

[0013] Figure 6 is a bottom view of the assembly shown in Figures 1 and 3;

[0014] Figure 7 is a plan view of the assembly shown in Figures 1 and 3 with the anchor and ferrule components improperly assembled;

[0015] Figure 8 is a top plan view of a seatbelt anchor assembly in accordance with in accordance with a third embodiment of this invention; [0016] Figure 9 is a bottom plan view of the assembly shown in Figure 8; [0017] Figure 10 is a side view of the seatbelt anchor assembly shown in

Figure 8; and

[0018] Figure 1 1 is an enlarged perspective illustration of the mating of the anchor and ferrule components of the embodiment shown in Figure 8.

DETAILED DESCRIPTION OF THE INVENTION [0019] A seatbelt anchor assembly in accordance with the first embodiment of this invention is illustrated in Figures 1 and 3. The anchor assembly includes a pair of primary structural components, including anchor 12, ferrule 14, and further has retaining clip 16. Figure 1 illustrates these components in an assembled position, whereas Figure 3 shows the parts in an exploded apart position. [0020] Anchor 12 is preferably formed from sheet metal stock and includes a connection end 18 which, in the embodiment illustrated, includes a central aperture 20 adapted to receive seatbelt webbing (not shown). Connection end 18 could alternatively mount a belt buckle or other belt restraint system component. Preferably, if webbing is routed through aperture 20, 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. Anchor 12 further includes a projecting plate end 22. In a preferred embodiment, plate end 22 includes a mid-section 24 and an end section 26. The end section 26 is wider than the mid-section 24, thereby forming a pair of shoulder surfaces 28 and 30. As it will be explained in more detail in the later description, it is preferred that shoulder surfaces 28 and 30 be "misaligned" or at different positions along the length of anchor 12 to prevent misassembly of the components. Anchor 12 further forms hole 32 adapted to receive a threaded fastener when the components are in their final assembled condition. The edges of anchor mid-section 24 are shown having a relieved radius edge 36 which provides clearance for mating contact with ferrule 14.

[0021] Ferrule 14 is also formed preferably from sheet metal stock and includes an end section 38 which is U-shaped in cross-section. End 38 forms a plate section 40 and a pair of rolled sides 42 and 44, each preferably forming extending hooks 46 and 48, and notches 50 and 52. Plate 40 further forms hole 54 which is oriented to align with hole 32 when the components are in their assembled condition for receiving a fastener such as threaded bolt 74.

[0022] In order to permit anchor assembly 10 to be adapted for various vehicle applications, ferrule 14 in a first embodiment forms a cable crimping sleeve 56. Sleeve 56 has a hollow interior for receiving a mounting cable (not shown) and can be crushed to firmly affix the cable to ferrule 14. Another end of the cable is mounted to a vehicle structural component.

[0023] In another embodiment of the invention illustrated in Figure 2, ferrule

14A features and extending strap 58 having a mounting aperture 60. Strap 58 can be directly mounted to a vehicle structural element through a threaded fastener connection passing through mounting aperture 60.

[0024] As illustrated particularly in Figures 1 and 3, retaining clip 16 includes a central bridge section 64 and a pair of V-shaped legs 66 and 68. The inner surfaces of legs 66 and 68 preferably includes ramp projections 70 and 72 such that clip 16 can be snapped into engagement with anchor 12. This occurs as the ramps 70 and 72 deflect as the clip is installed and snap against the face surface of anchor opposite the surface where bridge 64 is present. Anchor notches 71 and 73 receive ramps 70 and 72 to locate clip 16. Figure 2 shows the position of retaining clip 16 as it would be installed into snap connection engagement with anchor 12. Once clip 16 is assembled, it is maintained in connection with anchor 12.

[0025] Ferrule 14 is assembled in connection with anchor 12 by sliding them together in a manner causing compression of clip legs 66 and 68 enabling hooks 46 and 48 to clear shoulders 28 and 30. Once in this position, tension is applied to the parts causing them to move to their assembled position illustrated in Figure 1 . In this position, as best shown by Figure 4, hooks 46 and 48 interlock with anchor end section 26. Retaining clip legs 66 and 68 provide a compliant force urging anchor 12 and ferrule 14 into their assembled position as shown in Figure 1. In this assembled condition, the assembly may be handled and shipped and later threaded fastener 74 may be installed.

[0026] Since ferrule 14 is formed of sheet metal, a radius is formed at the junctions between plate section 40 and sides 42 and 44. When the parts are assembled, relieved edges 36 of anchor 12 provide clearance to accommodate the inside radii of ferrule 14.

[0027] As illustrated in Figure 3, shoulder surfaces 28 and 30 are positioned at different positions along the length of anchor 12. The corresponding engaging surfaces of ferrule 14 are also misaligned in the same manner as are the shoulder surfaces. Thus, in a properly assembled condition, the components will reach the position shown in Figure 1 in which case holes 32 and 54 align to receive the threaded fastener 74, shown in Figure 4 as bolt 74. However, if the parts are assembled improperly with the anchor 12 or ferrule 14 in an upside down position, the parts cannot reach their assembled condition as illustrated in Figure 7. As shown in that figure, holes 32 and 54 do not align and one of the hooks 48 does not engage the anchor shoulder 30, indicating improper assembly. The parts only fit together when ferrule plate 40 is placed against one face surface of anchor mid section 24, and not when placed against the opposite face surface. [0028] During the assembly process, ferrule 14 may be affixed to anchor 12 in the manner described above and handled as part of a seatbelt assembly. When the final assembly process is completed for the seatbelt system, threaded fastener 74 is installed through holes 32 and 54. As best illustrated in Figure 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 ferrule 14 or 14A may be used with anchor 17. [0029] A seatbelt anchor in accordance with a third embodiment of this invention is illustrated in Figures 8 through 1 1 . This anchor assembly 80 forms a pair of primary structural components similar to that of the first and second embodiments including anchor 82 and ferrule 84. This embodiment however, does not employ an element corresponding with retainer clip 16 described and shown in connection with the first and second embodiments. Figures 8 through 1 1 illustrate these components in an assembled condition. Anchor 82 is preferably formed from sheet metal stock and includes a connection end 86, which in the embodiment illustrated forms a central aperture 88 adapted to receive seatbelt webbing (not shown) for connection with an associated belt restraint system. Anchor 82 further forms a projecting plate end 90 forming mid-section 92 and end section 94. End section 94 is wider than mid-section 92 thereby forming a pair of shoulder surfaces 96 and 98. Anchor 82 further forms hole 102 adapted to receive a threaded fastener when the components are in their final assembled condition. Between connection end 86 and plate end 90, anchor 82 forms a narrowed neck section 91. [0030] Ferrule 84 is also preferably formed from sheet metal stock and includes end section 104 which is U-shaped in cross-section. End 104 forms a plate section 106 and a pair of rolled sides 108 and 1 10, each forming hooks 1 12 and 1 14 extending toward cable sleeve 130, and notches 1 16 and 1 18. Rolled sides 108 and 1 10 further form a second pair of hooks 132 and 134 with end bent toward the center of plate section 106. Plate 106 further forms hole 120 which is oriented to align with hole 102 when the components are in their assembled condition for receiving a fastener such as threaded bolt 74. Bushing 124 is welded to ferrule plate section 106 to provide additional thread engagement with fastener 74, to increase the clamping and retention force provided by the fastener. Fastener 74 is not shown with anchor assembly 80 but would be inserted through hole 102 to engage with bushing 124. In other words, the fastener would be inserted into engagement with the assembly as the components are shown in Figure 8.

[0031] Anchor end section 94 forms side edge sections 126 and 128 which are bowed or deflected toward ferrule plate section 106. This feature is best illustrated in Figures 10 and 1 1 .

[0032] Like the first embodiments, anchor assembly 80 includes features to prevent improper assembly of anchor 82 and ferrule 84. The proper assembled condition is illustrated in Figures 8 through 1 1. Anchor 82 and ferrule 84 are mated together and then pulled apart such that they slide relative each other until ferrule 84 and hooks 1 12 and 1 14 engage with shoulders 96 and 98. In this assembled condition, hooks 132 and 134, which fit into anchor neck section 91 when the parts are being assembled, also overlap the anchor mid-section 92. As best shown in Figure 1 1 , edges 126 and 128, having their formed curled configuration, allow hooks 1 12 and 1 14 to interlock with them. Once in the final assembled condition shown in Figures 10 and 1 1 , a threaded fastener 74 may be placed through holes 102 and 120 engaging with bushing 124.

[0033] Improper assembly of anchor assembly 80 is prevented since if an attempt were made to invert ferrule 84, the curled edges 126 and 128 would interfere with hooks 1 12 and 1 14. This would prevent the parts from reaching their final assembled condition in which holes 102 and 120 align, and thus placement of the fastener 84 is prevented.

[0034] In order to permit anchor assembly 80 to be mounted to the vehicle, ferrule 84 in the embodiment shown in Figures 8 through 1 1 , forms a cable crimping sleeve 122 which is similar to ferrule 14 in accordance with the first embodiment of this invention. As illustrated in the descriptions of the first and second embodiment, ferrule 84 could also be adapted to include a strap for mounting to the vehicle or some other feature for mounting could be provided.

[0035] This description defines a configuration of anchors 12 and 82 and ferrules 14 and 84 and 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 ferrule 14 or 84 could, in such an alternative configuration, have the features of anchor plate end 22 or 90, with the anchor 12 or 82 having the "U"-shaped cross-section shape with the sides and hooks described for the ferrule. [0036] While the above description constitutes the preferred embodiment of the present invention, it will be appreciated that the invention is susceptible to modification, variation and change without departing from the proper scope and fair meaning of the accompanying claims.