Retractor with Crushable Spool Insert

1 . A seat belt retractor ( 20 ) comprising

a spool ( 32 ) mounted for rotation to a frame ( 22 ); the spool ( 32 ) having a locked mode of operation and a freewheeling mode of operation,

one or both of a web sensor ( 50 ) and/or vehicle sensor for initiating lockup of the spool ( 32 );

a collapsible member ( 40 ) positioned about the circumference of the spool ( 32 ), the insert having a first end ( 102 ), a second end ( 104 ) and a middle therebetween, the insert initially positioned with the first end ( 102 ) secured to or otherwise located against the spool ( 32 ), the middle includes a plurality of undulations ( 112 a - 112 h ), formed by adjacent peaks and valleys, each valley configured to initially lie in close proximity to the circumference of the spool ( 32 ), the second end ( 104 ) of the insert initially positioned adjacent and spaced from the first end ( 102 ) and configured to slide over the first end ( 102 ) during operation.

2 . The retractor ( 20 ) according to claim 1 wherein the seat belt ( 411 ) upon exiting the slot ( 70 ) is rolled about the undulations ( 112 a - 112 h ) of the insert and wherein the second end ( 104 ) of the insert is configured to slide in between an adjacent loop of the seat belt ( 411 ) and be covered by another loop of the seat belt ( 411 ).

3 . The retractor ( 20 ) according to claim 2 wherein during an accident the seat belt ( 411 ) is stressed by an applied force, and with the spool ( 32 ) locked this force migrates through the number of loops located about the insert, causing the undulations ( 112 a - 112 h ) to be pressed against the center of the spool ( 32 ).

4 . The seat belt retractor ( 20 ) according to claim 2 wherein the seat belt ( 411 ) is stressed radially and tangentially in relation to the spool ( 32 ) by an applied force, causing the loops of seat belt ( 411 ) about the collapsible member ( 40 ) to tighten about the collapsible member ( 40 ), wherein this tightening force is an inward radial force, acting in one direction to crush or compress the undulations ( 112 a - 112 h ) toward the spool ( 32 ) and also radially push a loose end ( 104 ) of the member between two layers of seat belt ( 411 ).

5 . The seat belt according to claim 1 wherein the collapsible member ( 40 ) is made from one of spring steel, heat treated steel, plastic or composite foam.

6 . A method of controllably retarding forward movement of a vehicle occupant ( 404 ) in a crash when using a system, the system comprising:

a) a multi-point seat belt system comprising a seat belt retractor ( 20 ) with a spool ( 32 ), the spool having a locked mode of operation and a freewheeling mode of operation,

b) a seat belt ( 411 ) characterized as having a known elongation rate under stress,

c) a collapsible member ( 40 ) wrapped about a center or body portion of the spool ( 32 ) of the retractor ( 20 ), the member ( 40 ) having an initial diameter d 1 when unstressed and collapsible to a lesser diameter of d 2 under stress;

the method comprising the steps of:

a) sensing an accident and locking the spool ( 32 ) from rotating;

b) permitting the occupant ( 404 ) to move forward and load the seatbelt;

c) permitting the seat belt ( 411 ) to elongate and in doing so dissipating the energy acting on the occupant ( 404 ) during the crash;

d) transferring the occupant's crash force on the seat belt ( 411 ) to a compressive force to tend to collapse the member ( 40 );

e) generating a retarding force on the occupant ( 404 ) in proportion to the degree by which the collapsible member ( 40 ) collapses.

7 . The method according to claim 6 wherein f) permitting a free portion or end of the collapsing member ( 40 ) to slide between adjacent loops of the seat belt ( 411 ) as the collapsing member ( 40 ) collapses.

8 . The method according to claim 7 including the step of permitting seat belt ( 411 ) (webbing) to pay out in proportion to the degree by which the member ( 40 ) has (radially) collapsed.

9 . The method according to claim 6 wherein prior to the initiation of collapsing of the member ( 40 ), there are X rolls of seat belt looped about the center portion of the spool ( 32 ) and wherein as the seat belt ( 411 ) is permitted to pay out the number of loops remains the same.

10 . The method according to claim 6 wherein the payout of the seat belt ( 411 ) is controlled by the shape of the undulation or height and length describing the undulation.

11 . The method according to claim 2 wherein the collapsing member ( 40 ) is formed out of plastic.

12 . The method according to claim 1 wherein the collapsing member ( 40 ) is formed out of spring hardened steel, a composite plastic and polymeric foam material.