Structure for use in a seat belt retractor and method of using the structure to make a seat belt retractor

A structure for use in a seat belt retractor having a frame, a spool supported in the frame and rotatable in belt winding and unwinding directions, a spring member biasing the spool in the belt winding direction, and a spring cover attachable to the frame for enclosing the spring member, said structure comprising:

• a first plastic portion having a generally U-shape and comprising at least a part of the frame of the retractor;
• a second plastic portion comprising the spring cover;
• and
• a first plastic hinge portion interconnecting said first and second plastic portions for enabling said first and second plastic portions to pivot relative to each other.

A structure for use in a seat belt retractor having a frame, a spool supported in the frame and rotatable in belt winding and unwinding directions, a spring member biasing the spool in the belt winding direction, and a spring cover attachable to the frame for enclosing the spring member, said structure comprising:

• a first plastic portion and a second plastic portion to which the spring cover is attachable to enclose the spring and on which the spool is supportable to rotate in the belt winding and unwinding directions;
• a metal portion insert molded into said first and second plastic portions and interconnecting said first and second plastic portions to form a generally U-shape and to comprise at least a part of the frame of the retractor;
• a plastic tie bar portion located opposite said metal portion and interconnecting said first and second plastic portions to support said first and second plastic portions, said plastic tie bar portion and said first and second plastic portions comprising a homogeneous plastic material;
• said structure further including a third plastic portion comprising the spring cover;
• and
• a plastic hinge portion interconnecting said second and third plastic portions for enabling said second and third plastic portions to pivot relative to each other.

A structure for use in a seat belt retractor having a frame, a spool supported in the frame and rotatable in belt winding and unwinding directions, a spring member biasing the spool in the belt winding direction, and a spring cover attachable to the frame for enclosing the spring member, said structure comprising:

• a first plastic portion and a second plastic portion to which the spring cover is attachable to enclose the spring and on which the spool is supportable to rotate in the belt winding and unwinding directions;
• a metal portion insert molded into said first and second plastic portions and interconnecting said first and second plastic portions to form a generally U-shape and to comprise at least a part of the frame of the retractor;
• and
• a plastic tie bar portion located opposite said metal portion and interconnecting said first and second plastic portions to support said first and second plastic portions, said plastic tie bar portion and said first and second plastic portions comprising a homogeneous plastic material.

A structure for use in a seat belt retractor having a frame, a spool supported in the frame and rotatable in belt winding and unwinding directions, a spring member biasing the spool in the belt winding direction, and a cover attached to the frame for enclosing the spring member, said structure comprising:

• a homogeneous plastic material having at least first and second portions and first hinge means for hingedly interconnecting said first and second portions for enabling said first and second portions to pivot relative to each other and into position with said first and second portions comprising at least a part of the frame of the retractor;
• said homogeneous plastic material having a third portion comprising the spring cover;
• and
• said homogeneous plastic material having second hinge means for hingedly connecting said third portion to one of said first and second portions of said homogeneous plastic material for enabling said portions to pivot relative to each other and into position with said third portion and said one of said first and second portions enclosing the spring member.

A method of making at least a part of a seat belt retractor having a frame, a spool supported in the frame and rotatable in belt winding and unwinding directions, a spring member biasing the spool in the belt winding direction, and a sensor member, said method comprising the steps of:

• providing a structure having a first plastic portion for comprising at least a part of the frame of the retractor, a second plastic portion for comprising a cover for one of the members, and a first plastic hinge portion interconnecting the first and second plastic portions;
• providing a frame including the step of moving the first plastic portion into a position to comprise at least a part of the frame of the retractor;
• mounting the spool in the frame of the retractor to support the spool for rotation in belt winding and unwinding directions;
• operatively connecting the spring member to the spool to bias the spool in the belt winding direction;
• mounting the sensor member on the frame of the retractor;
• and
• pivoting the first and second plastic portions relative to each other and into a position with the second plastic portion covering the one of the members.

A method of making at least a part of a seat belt retractor having a frame, a spool supported in the frame and rotatable in belt winding and unwinding directions, a spring member biasing the spool in the belt winding direction, and a spring cover attachable to the frame for enclosing the spring member, said method comprising the steps of:

• providing a generally U-shaped first plastic portion for comprising at least a part of the frame of the retractor, a second plastic portion for comprising the spring cover, and a first plastic hinge portion interconnecting the first and second plastic portions;
• mounting the spool between the legs of the generally U-shaped first plastic portion to support the spool for rotation in belt winding and unwinding directions;
• operatively connecting the spring member to the spool to bias the spool in the belt winding direction;
• and
• pivoting the first and second plastic portions relative to each other and into a position with the second plastic portion covering the spring member.

A method for making at least part of a seat belt retractor having a frame, a spool supported in the frame and rotatable in belt winding and unwinding directions, a spring member biasing the spool in the belt winding direction, and a spring cover attachable to the frame for enclosing the spring member, said method comprising the steps of:

• providing a structure having (i) a first plastic portion comprising at least a part of the frame, (ii) a second plastic portion comprising at least a part of the frame and to which the spring cover is attachable to enclose the spring and on which the spool is supportable to rotate in the belt winding and unwinding directions, (iii) a metal portion insert molded into the first and second plastic portions and interconnecting the first and second plastic portions to form a generally U-shape and to comprise at least a part of the frame, and (iv) a plastic tie bar portion located opposite the metal portion and interconnecting the first and second plastic portions to support the first and second plastic portions;
• mounting the spool between the legs of the generally U-shaped structure to support the spool for rotation in belt winding and unwinding directions;
• operatively connecting the spring member to the spool to bias the spool in the belt winding direction;
• further comprising the steps of providing a third plastic portion connected to the second plastic portion and comprising the spring cover, and pivoting the second and third plastic portions relative to each other and into a position with the third plastic portion covering the spring member.

A method for making at least part of a seat belt retractor having a frame, a spool supported in the frame and rotatable in belt winding and unwinding directions, a spring member biasing the spool in the belt winding direction, and a spring cover attachable to the frame for enclosing the spring member, said method comprising the steps of:

• providing a structure having (i) a first plastic portion comprising at least a part of the frame, (ii) a second plastic portion comprising at least a part of the frame and to which the spring cover is attachable to enclose the spring and on which the spool is supportable to rotate in the belt winding and unwinding directions, (iii) a stamped metal portion insert molded into the first and second plastic portions and interconnecting the first and second plastic portions to form a generally U-shape and to comprise at least a part of the frame, and (iv) a plastic tie bar portion located opposite the metal portion and interconnecting the first and second plastic portions to support the first and second plastic portions;
• mounting the spool between the legs of the generally U-shaped structure to support the spool for rotation in belt winding and unwinding directions;
• and
• operatively connecting the spring member to the spool to bias the spool in the belt winding direction.

A structure for use in a seat belt retractor having a frame, a spool supported in the frame and rotatable in belt winding and unwinding directions, a spring member biasing the spool in the belt winding direction, and a spring cover attachable to the frame for enclosing the spring member, said structure comprising:

• a first plastic portion and a second plastic portion to which the spring cover is attachable to enclose the spring and on which the spool is supportable to rotate in the belt winding and unwinding directions;
• a stamped metal portion insert molded into said first and second plastic portions and interconnecting said first and second plastic portions to form a generally U-shape and to comprise at least a part of the frame of the retractor;
• and
• a plastic tie bar portion located opposite said metal portion and interconnecting said first and second plastic portions to support said first and second plastic portions, said plastic tie bar portion and said first and second plastic portions comprising a homogeneous plastic material.

A method for making at least part of a seat belt retractor having a frame, a spool supported in the frame and rotatable in belt winding and unwinding directions, a spring member biasing the spool in the belt winding direction, and a spring cover attachable to the frame for enclosing the spring member, said method comprising the steps of:

• providing a structure having (i) a first plastic portion comprising at least a part of the frame, (ii) a second plastic portion comprising at least a part of the frame and to which the spring cover is attachable to enclose the spring and on which the spool is supportable to rotate in the belt winding and unwinding directions, (iii) a stamped metal portion insert molded into the first and second plastic portions and interconnecting the first and second plastic portions to form a generally U-shape and to comprise at least a part of the frame, and (iv) a plastic tie bar portion located opposite the metal portion and interconnecting the first and second plastic portions to support the first and second plastic portions;
• mounting the spool between the legs of the generally U-shaped structure to support the spool for rotation in belt winding and unwinding directions;
• and
• operatively connecting the spring member to the spool to bias the spool in the belt winding direction.