Abstract: A seat belt retractor for use in seat belt restraint systems. The retractor incorporates dual rotopretensioner units and adaptive load limiting characteristics. Preferably, the rotopretensioners are positioned on opposite ends of a retractor spool for driving the spool for pretensioning rotation. A first pretensioner may be activated alone to provide pretensioning rotation. In one embodiment of the invention, if the second pretensioner is not activated, the system will be engaged to provide a given belt load limiting characteristic. A second rotopretensioner may be fired either after the first pretensioner is fired to increase pay-in capacity or to activate a different load limiting characteristic for the retractor.

Abstract: A torsion bar, constructed in accordance with the teachings of the present invention, an elongated bar has a first end, a second end, and a mid-section between the first and second ends. The first end of the elongated bar has a material void. The first end preferably has a diameter substantially equal to a diameter of the mid-section. In one design, the material void is a slot extending longitudinally, and the first end may also define a plurality of circumferentially spaced slots extending longitudinally. In another design, the material void is a bore extending longitudinally, and the first end may also define a plurality of slots extending longitudinally and extending from the bore through an exterior surface of the elongated bar to leave a plurality of fingers at the first end. In these designs and other, the torsion bar and the material void may be cold forged, thereby eliminating a second forming step.

Abstract: A torsion bar, constructed in accordance with the teachings of the present invention, an elongated bar has a first end, a second end, and a mid-section between the first and second ends. The first end of the elongated bar has a material void. The first end preferably has a diameter substantially equal to a diameter of the mid-section. In one design, the material void is a slot extending longitudinally, and the first end may also define a plurality of circumferentially spaced slots extending longitudinally. In another design, the material void is a bore extending longitudinally, and the first end may also define a plurality of slots extending longitudinally and extending from the bore through an exterior surface of the elongated bar to leave a plurality of fingers at the first end. In these designs and other, the torsion bar and the material void may be cold forged, thereby eliminating a second forming step.

Abstract: A seat belt load limiter employs a magnetostrictive sensor to detect the elastic loading and plastic deformation of a torsion rod forming part of a seat belt retractor. A magnet and a coil are placed about or adjacent to the torsion rod. When the torsion rod undergoes elastic or plastic strain, an electrical voltage is induced in the coil which is used to detect elastic or plastic strain of the torsion rod. A vehicle safety system uses the output of the magnetostrictive sensor to inform the vehicle operator when the seat belt load limiter is in need of replacement. The output of the magnetostrictive sensor as processed by the vehicle safety system can also be used to detect a situation where the seat occupant is not restrained by the seat belt and to make an airbag deployment decision.

Abstract: An energy absorber for protecting the occupants of a vehicle. The energy absorber includes an interior portion and a first contact surface at least partially surrounding the interior portion. The first contact surface is attachable to a structural member of the vehicle. The energy absorber also includes at least one hollow cavity extending through the interior portion in a direction substantially parallel to the first contact surface. During a vehicle collision, the first contact surface absorbs energy from occupant impact with an interior trim piece by deforming into the hollow cavity.

Abstract: An energy absorber for protecting the occupants of a vehicle is disclosed. The energy absorber includes an interior portion. A first contact surface at least partially surrounding the interior portion is also provided. The first contact surface is attachable to a structural member of the vehicle. The energy absorber also includes at least one hollow cavity extending through the interior portion in a direction substantially parallel to the first contact surface. During a vehicle collision, the first contact surface absorbs energy from occupant impact with an interior trim piece by deforming into the hollow cavity.

Abstract: An automotive door panel that has styling lines is made by laying a facing layer of soft trim material on a support surface of a mold part. The facing layer has a backing layer of open cell flexible foam that has gaps that expose strips on the back surface of the facing layer. A heat-sensitive adhesive barrier film is behind the flexible foam backing layer. The mold is closed by a mating mold part and a urethane precursor mixture is injected into the closed mold which is heated to generate a structural substrate. The generating substrate crushes the backing layer and activates the adhesive film to bond the structural substrate to the exposed back surface strips of the facing layer to provide the styling lines. These styling lines are enhanced when the foam backing layer recovers upon removal from the mold.