Abstract: A crash detection system comprises two sensors with complementary performance characteristics, a controller evaluates the signals from both sensors to determine whether an airbag should be activated, when an airbag should be activated and whether multiple stages of the airbag should be activated. The first sensor preferably comprises a ball-in-tube sensor and the second sensor preferably comprises an electronic sensing module comprising an accelerometer and a CPU. The CPU receives signals from the accelerometer and the ball-in-tube sensor. The controller activates the airbag only if both sensors generate fire signals. The controller generates an airbag activation signal based upon crash type and the sum of the times required from the beginning of the crash for both sensors to generate fire signals.

Abstract: A safety apparatus including an air bag (20). The air bag includes a first (22) and second (24) panel of flexible, impermeable material, each panel having a respective peripheral edge (23,25). The first and second panels are joined together along a structural first joint (110), which extends along a substantial portion of the peripheral edges to define an inflatable chamber (26) therebetween. The first joint (110) is subject to a peel load as the first and second panels are urged apart as the chamber is inflated. The apparatus also includes inlet means (32, 44) for communicating inflation gas into the chamber. A pressure barrier (100) is located within the chamber, for preventing inflation gas from bearing against the first joint. In the preferred embodiment, the pressure barrier is not subject to the peel load as is the first joint.

Abstract: An air bag module (20) comprising: a housing (22) having a first opening (102) within a first housing portion (100), a retaining member (24) having a second opening (52) and at least one pair of opposed open faced ramps (40a,b), an air bag (26) having an inflatable cushion portion (80) and a neck portion (82), the neck portion is located between the housing and retaining member (24), a cover (30) to protect the air bag, the cover being opened by the air bag upon inflation thereof, and an inflator (28) received within the first opening from a bottom of the first housing portion (100) and into the second opening (52), the inflator including a flange (36); wherein with an edge of the inflator flange located proximate a respective open face of a ramp and the inflator rotated, the flange engages the ramps and is drawn toward the retaining member thereby sandwiching the housing and air bag therebetween.

Abstract: A force-sensing mechanism (20) comprising: a housing having first (22) and second (24) housing members; a slidable plate positioned between plate portions of the first and second housing members and moveable thereto; various spacers located between the first housing member and the sliding plate to space and stabilize the plate relative to the first and second housing members; a magnetic sensor stationarily mounted between the first and second housing members, a magnet moveable with the sliding member in response to forces applied to the first and second housing members and to the sliding plate; a spring assembly (250) having one end in operative engagement with the sliding plate and another end in operative engagement with the housing while biasing the sliding plate within the housing.

Abstract: An apparatus for detecting a force applied using a pressure sensor, an alternating voltage applied to the pressure sensor, and means for detecting the output voltage from the sensor to determine the force applied. One embodiment applies the alternating voltage using a DC input voltage and a microcontroller for switching the voltage applied to the sensor.

Abstract: An acceleration-sensing mass/magnet is positioned about the center activation region of a reed switch. Motion of the acceleration-sensing magnet in either direction along the reed switch causes the reed switch to close. A first mechanism for sensing shock in a first direction is contained between a flange and a lid connected by a cylindrical wall. The flange and lid ride a plastic tube that contains the reed switch. The acceleration-sensing magnet travels between the flange and the lid on the tube. A second mechanism for sensing shock in a second opposed direction is formed by positioning a second mechanism about the magnet and the first mechanism. The second mechanism for sensing shock has a spring that biases the lid of the plastic sleeve against an abutment formed by a portion of a plastic capsule that encloses the entire shock sensor.

Abstract: A driver air bag module (22) having a cover (16), a cushion (12), an inflator (10), and a switch assembly (20) is disclosed. The switch assembly (20) is formed by a flat upper housing member (40), which is slideably coupled to a generally flat lower member (42). A pair of electrical contacts (43, 44) is disposed therein and is coupled to the generally flat lower member (42). The switch assembly (20) is coupled to an inflator (10) and incorporated into the air bag cushion (12).

Abstract: The subject invention is an apparatus and method for installing a cushion into a cover to provide for a uniform and consistent thickness of cushion between an inflator/horn assembly and the cover such that variation in the amount of force applied to the cover is minimized. The apparatus for installing the cushion to the cover includes a base for supporting the cover, a housing defining a cavity and having an upper and a lower platform, an air bag housing and a mock inflator attached to a piston. The method includes the steps of attaching the cushion assembly to a mock inflator, securing the cover, compacting the cushion into the cover and around the mock inflator, such that the cushion fills the cavity of the cover; then removing the mock inflator from the cushion to form a cavity within the cushion for the inflator/horn assembly.

Abstract: A gear shift assembly including a knob with a body has a shaft that is adapted for receiving the gearshift knob. A fastener is mounted within the body of the gearshift knob for removably securing the gearshift knob to the shaft. The fastener further includes a resilient inner flange for interacting with the gear shift shaft to removably secure said gear shift knob to said gear shift shaft to prevent the gear shift knob from sliding off of the shaft or from rotating about the shaft.

Abstract: A seat belt retractor comprising: a spool about which a seat belt is wound; a locking mechanism at least initially locking the spool against rotation and a primary force-limiting mechanism, such as a torsion bar for permitting the spool to rotate in a controlled manner subsequent to the locking of the spool and a secondary force-limiting mechanism located within a recess of the spool and comprised from portions of the spool and an adjacent portion of the locking mechanism for increasing the restraining force on the seat belt before the primary force-limiting mechanism becomes effective. The torsion bar is connected at one end to the spool and at its other end to the locking mechanism. The secondary locking mechanism includes a recess, keyway or slot and a projecting, breakable tab formed on one of the bore and an interfitting part of the locking mechanism.

Abstract: A seat belt retractor (20) characterized by low mass and low operating noise, resistant to dust, moisture, and corrosion comprising: an integrally formed, quadrilaterally shaped main body portion (24). In the preferred embodiment, the frame is injection molded using 50% or greater long glass fiber plastic or die cast or injection molded metal. A spring housing wall and wall of a mechanism cover are also integrally formed in the sides of the retractor. Positioned within the spring housing wall is a spring coil guide, as well as an integrally formed anchor, which is used to hold the outer end of a rewind spring. The mechanism side of the frame further includes an integrally formed post or pin to pivotally support a locking pawl.

Abstract: A unique and simple method for attaching a steering wheel to a steering shaft includes a pair of securement members. The steering shaft is provided with a slot extending into an enlarged space. The first securement member extends across a bore in the steering wheel, and is threadably received in the second securement member. The steering wheel can be moved onto the steering shaft with the first securement member moving through the slot and into the space. The first securement member can then draw the second securement member into the space. Preferably, there is a tapered interface between the second securement member, the steering wheel, and the steering shaft. The tapered surface drives the steering wheel downwardly onto the steering shaft such that a wedge-lock is provided. In a further feature of this invention, an outer housing surrounds the steering shaft. The outer housing has a pair of spaced slots.

Abstract: Two parts of a seat belt retractor spool sub-assembly are fixed together in an arrangement with plastically deformable formations on a first ratchet wheel and one end of a spool and corresponding deforming formations on a second ratchet wheel and said one end of the spool. A spool for a seat belt retractor is assembled with a ratchet wheel by: mounting a retractor frame on an assembly jig which has a spring loaded stop; mounting a spool in the frame by aligning the spool axis with the spring loaded stop; and pushing a ratchet wheel onto the end of the spool opposite to that contacting the stop until the ratchet wheel abuts the frame.

Abstract: A pretensioner for a vehicle occupant safety restraint has an outer casing that contains a gas generant. An igniter has igniter material disposed within an igniter housing. A pair of electrodes are connected to the igniter material. A grounding path connector link electrically connects the igniter housing to a grounding path. The connector link may be formed by springs connecting the outer case to the grounding electrode and an interference fit connecting the igniter housing to the outer case. The link forms a low resistance path to short circuit undesirable static charges in the unit that would otherwise tend to cause unintentional activation of the pretensioner.

Abstract: An air bag module (20) including: an inflator (30); a cushion (26); a retainer ring (28); a cover (22) having a relatively flexible side wall (48a-d) with a pair of flaps (50a,50b) integrally formed and extending from opposing portions of the flexible side wall, each of the flaps including a plurality of apertures (60;62); a housing (24) having a bottom, and a side wall enveloping an end region of the cover side wall to reinforce the cover side wall; and a first plurality of fasteners (82) for engaging the inflator, retainer ring, the cushion (26) and cover flaps.

Abstract: A seat belt retractor with a belt reel upon which the seat belt can be wound and unwound, and a force limiter composed of a deformable material which is arranged between at least one first reel part which can be blocked by a blocking device against rotation and at least one second reel part which is rotatable upon energy consumption of the force limiter, an inertial mass being capable of being coupled to the second reel part for entrainment by means of a coupling which is engaged upon blocking of the first reel part and rotation of the second reel part.

Abstract: A seatbelt buckle tongue has a buckling part and an aperture through which seatbelt webbing passes. The extent of sliding of the tongue on the webbing is limited by at least one protrusion provided on the inside of the aperture in the tongue. A protrusion may be round, square or formed of a line of a plurality of buttons dimensioned and arranged to apply pressure to the webbing passing through the tongue and resist sliding of the tongue on the webbing.

Abstract: An automatic seatbelt retractor has a winding shaft for winding and unwinding seatbelt webbing and at least one pre-locking device for pre-locking the winding shaft against further rotation and for driving into a main locking means. Forces exerted by the seatbelt webbing are introduced into a frame connected to a vehicle. The pre-locking device has an actuating device that actuates at least one securing component as a function of a predetermined extracted length of the seatbelt webbing from the winding shaft to hold the winding shaft in the pre-locking position. For actuation of the securing component by the actuating device a single intermediate element, which can be moved reversibly by the actuating device from a rest position into a locking position, is provided between the actuating device and the securing component.

Abstract: A force sensor (50, 50′, 50a) generates a signal indicating the usage of a seat belt. A cylindrical housing (70, 70′) has a wall (72) and a bottom (74) which define an internal cavity (124). The bottom has an opening (76) through it. A cable anchor (90) is slidably received within the cavity and is connected to a cable (54). The cable has one end secured to the cable anchor and another end connected to an anchor point. A magnet (120) is connected to a top of the cable anchor and is movable with the cable anchor. The cable anchor is biased to resist motion of the cable anchor toward the bottom of the housing. A magnetic sensor (200) for generates a signal indicative of the distance between it and the magnet. A sensor housing (180) is connected to the housing and is positioned on the housing to position the magnetic sensor a determinable distance from the magnet at a null position. A housing end cap (150) is secured to the housing for enclosing an open end of the housing.