DEFECTIVE CHILD CAR SEATS
Car Seat Injury Lawsuits
investigating defective child car seats & car seat recalls
Product liability law exists precisely for situations where defective products cause harm. Manufacturers who place products into commerce bear strict liability when design defects, manufacturing defects, or warning inadequacies result in injuries.
Design defect claims challenge fundamental product engineering. If safer alternative designs existed at reasonable cost, manufacturers had obligations to implement them. Car seat makers cannot claim ignorance when safer harness systems, stronger materials, or better installation mechanisms were available but not utilized.
Manufacturing defect theories apply when individual products deviate from intended specifications. Quality control failures that allow defective units to reach consumers create liability regardless of whether the design itself was sound.
Failure-to-warn claims address inadequate instructions or missing safety information. When manufacturers know about potential hazards but fail to adequately communicate risks, they bear responsibility for resulting injuries.
The Hidden Dangers Lurking in Car Seat Design
Modern parents face overwhelming choices when selecting car seats. Marketing materials promise cutting-edge safety features, advanced side-impact protection, and rigorous testing protocols. Yet serious defects continue emerging even in widely-purchased models from major manufacturers.
Harness system failures represent one critical vulnerability. Chest clips that release under impact force. Buckles that spontaneously open. Straps that loosen rather than lock during collisions. When restraint systems don’t actually restrain, children become projectiles inside vehicles or get ejected entirely.
Structural integrity issues pose equally serious threats. Seat shells that crack on impact instead of absorbing energy. Bases that detach from vehicle anchors. Materials that become brittle in normal temperature ranges, compromising crash performance. These fundamental design flaws undermine every safety claim manufacturers make.
Installation complexity creates another dimension of danger. Some seats feature such confusing installation requirements that even careful parents cannot properly secure them. When products require PhD-level instructions to use correctly, the fault lies with designers, not users. Manufacturers bear responsibility for creating intuitive, foolproof installation systems.
Then there’s the testing inadequacy problem. Many car seats meet minimum federal standards yet fail to protect children in real-world collision scenarios. Companies that market products as exceeding standards while knowing their limitations engage in deceptive practices that endanger purchasers’ children.
According to the U.S. Centers for Disease Control and Prevention (CDC), motor vehicle accidents are the leading cause of death for children in the United States, many, many cases that involve defective car seats.
Many young passenger injuries and deaths are preventable. The causes of accidents vary widely, but parents can take measures to reduce the risks on the road for their children.
One CDC study found that, in one year, more than 618,000 children ages 0-12 rode in vehicles without the use of a child safety seat or booster seat or a seat belt some of the time. Safe driving behavior and placing kids in appropriately-sized car seats, child seats and booster seats can be the difference between life and death.
Responsibility also lies with the manufacturing of reliable auto safety features and critical safety products like child car seats and baby seats. Car manufacturers and producers of child protection products have a duty to ensure the safety of America’s youth.
A properly designed and correctly used restraint system can reduce the risk of death of infants in passenger cars by up to 70 percent. However, when car seats or baby seats are defective, it may provide no protection at all, and may pose numerous dangers.
Joe Lyon is a highly-rated product liability lawyer and experienced personal injury attorney, well-versed in the science and economic impact auto accidents have on a victim’s life and family.
Common Types of Defective Car Seats
The National Highway Traffic Safety Administration (NHTSA) tested 66 infant seats in frontal crashes, and almost half of the seats either separated from their bases or exceeded the expectations of injury. Common defects with infant and child car seats include issues with handles, cheap materials, buckle defects, improper padding and component separation risks.
Design and manufacturing flaws leading to seat recalls have included:
- Defective Buckles—faulty or poorly designed buckles may unlatch upon impact, or allow a child to unfasten it.
- Defective Chest Clips—chest clips and harness straps may break or become unfastened, leading to serious injuries with or without a collision.
- Defective Carry Handles—some detachable car seats for infants have been recalled when handles released unexpectedly, causing the seat to move or fall in a moving vehicle.
- Inadequate Safety Padding—the cushions in a car seat are intended to prevent or reduce head injuries in the event of a collision. Insufficient padding can contribute to serious head or brain injuries.
- Defective Base Units—detachable car seats are latched into a base unit that may be defective. As a result, the car seat can unlatch upon impact, causing an infant or child to be thrown from the seat.
- Inadequate Installation Instructions—unclear instructions for installing or using a car seat can lead to misuse and subsequent injuries.
Recalled Defective Car Seats
Each year, there are several instances when a manufacturer or a safety agency issues a recall for a defective child seat that fails to protect young passengers. If you believe you have a defective car seat, or an injury has already occurred, contact the National Highway Traffic Safety Administration to report the problem, and contact an experienced attorney to investigate.

Baby Seat Defects & Recalls
Other brands of recalled or defective car seats may include:
- Britax Child Safety Inc. has also been actively recalling child seats in recent years. The company recalled 70,000 seats in 2016. Britax has recalled products for a defective harness chest clip, handles that may break, structural cracking, a loosening harness, and choking hazards.
- Baby Jogger LLC—a 2016 recall included the City Go infant car seat, the City Mini infant car seat, and the Vue Lite infant car seat. These baby seats fail to comply with certain requirements of Federal Motor Vehicle Safety Standard because of missing information in the instructions.
- Baby Trend Inc.—a February, 2017 recall was issued after it was discovered the child seats have a center adjuster rivet that may pull through or break if the harness is being used with a child weighing more than 40 lbs. As such, these child seats fail to comply with the requirements of Federal Motor Vehicle Safety Standard, and the child seat occupant may be at an increased risk of injury.
- Combi USA, Inc.—Combi has recalled their Coccoro and Zeus models for insufficient safety belts and harness webbing that fails to meet minimum breaking strength requirements. Both issues may increase the risk of injury in the event of an accident.
- Diono (formerly Sunshine Kids Juvenile)—Diono recalled the Radian R100, Radian R120, Radian RXT, Olympia, Pacifica, and Rainier convertible and booster car seats because the product may not adequately protect a child from injury in the event of a crash.
- Dorel Juvenile Group (DJG)—Dorel has issued six recalls in recent years for several child seat models. Safety concerns include inadequate latch assembly, poor instructions, defective harness buckles, improper base mounting, and difficulty attaching baby seats.
The following companies have also issued recent recalls for car seats for children:
- Orbit Baby Inc.
- Kiddy USA
- Peg Perego U.S.A.
- Lerado Success
- Recaro
- Team-Tex America
- Graco Children’s Products
- Triple Play Products
- Thorley Industries
Defective Child Car Seats
A study of five states that increased the child car seat/booster seat age requirement to 7 or 8 years found that the rate of children who sustained fatal or catastrophic injuries decreased by 17 percent. One safety organization recommends the following protocol:
Step 1: Rear-Facing Seats
Infants should start in a rear-facing car seat in the back seat. Rear-face until they reach the upper weight and height limits of the seat, past age 2. Keep rear-facing as long as possible. Leg crowding is expected which does not harm the child.
Step 2: Forward Facing Seats with Harnesses
When a child outgrows a rear-facing seat, use a forward-facing car seat with a harness and tether in the back seat. Use a car seat with a harness and tether until age 5, or until they outgrow the height and weight limits for the harness.
Step 3: Booster Seats
When your child passengers outgrow the forward-facing car seat with harness, use a booster seat. Use a booster seat until an adult seat belt fits correctly.
Step 4: Seat Belts
Child passengers are ready for a seat belt when the shoulder strap crosses the center of the chest and rests on the shoulder (not the neck). The lap belt should fit on the upper thighs near hips (not the stomach). Knees should be able to bend, and feet should be flat on the floor.
When Safety Equipment Fails: The Devastating Reality of Car Seat Defects
Parents strap their children into car seats with absolute faith. Every click of a buckle, every adjustment of a harness represents trust—trust that manufacturers have engineered these products to perform their singular, critical function: protecting small bodies during collisions.
That trust shatters when design flaws, manufacturing shortcuts, or inadequate testing turn protective equipment into sources of additional harm. A child who should have walked away from a minor fender-bender instead suffers catastrophic injury. A restraint system that promised five-star safety ratings fails at the moment of truth.
These aren’t acceptable manufacturing margins or unavoidable accidents. They’re preventable tragedies resulting from corporate decisions that prioritized cost savings over children’s lives.
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ABOUT THE LYON FIRM
Joseph Lyon has 17 years of experience representing individuals in complex litigation matters. He has represented individuals in every state against many of the largest companies in the world.
The Firm focuses on single-event civil cases and class actions involving corporate neglect & fraud, toxic exposure, product defects & recalls, medical malpractice, and invasion of privacy.
NO COST UNLESS WE WIN
The Firm offers contingency fees, advancing all costs of the litigation, and accepting the full financial risk, allowing our clients full access to the legal system while reducing the financial stress while they focus on their healthcare and financial needs.
Why The Lyon Firm Should Handle Your Car Seat Injury Case
Product liability litigation against major manufacturers demands substantial resources, specialized expertise, and unwavering commitment. The Lyon Firm brings decades of experience holding corporations accountable when defective products harm children.
We maintain relationships with leading engineers, safety experts, and medical specialists who provide credible testimony demonstrating how products failed and what injuries resulted. Our investigative capabilities include accessing industry documents, identifying similar incidents, and uncovering corporate knowledge of defects.
These cases require significant upfront investment in expert analysis and testing. The Lyon Firm has the financial strength to fund comprehensive litigation without asking families to pay costs during pending cases. Our contingency fee structure means attorney fees come only from recovery—you pay nothing unless we win.
We’ve secured substantial verdicts and settlements in product liability matters, forcing manufacturers to improve designs and compensating families for devastating losses. More importantly, we understand the profound emotional dimensions of representing parents whose trust was betrayed by companies that should have prioritized their children’s safety.
CONTACT THE LYON FIRM TODAY
Questions about Defective Car Seats
Product liability lawsuits often contain causes of action for strict liability, negligence, and breach of warranty. Strict liability applies to different factors than negligence-based claims.
In negligence cases, the actions of the defendant are the focus. In strict liability claims, the focus is on the condition of a product at the time it left the manufacturer. If a child car seat is determined to be defective, the company is liable for any foreseeable injuries that are in-part caused by the defective condition of the product.
A car seat is defective if it is unreasonably dangerous for its intended use. A legal cause of action can be based on several types of product defects. The following are Cincinnati product liability and strict liability claims available in Ohio and in most jurisdictions nationwide:
(1) Manufacturing/ Construction Defect:
These issues arise where the product is released from the factory in a manner that deviates from the intended design or specifications. The defect can be a result of using the wrong materials, including the wrong or completely foreign materials.
As a result of the deviation, the product enters the market in an unreasonably dangerous condition and the consumer is exposed to or purchases a product that is defective. Any personal injuries or economic loss that arise from the the defect are compensable under Ohio product liability law.
(2) Defective design and/or formulation:
Defective design product liability cases arise not because a mistake was made during the manufacturing process, but rather the original design of the product is unreasonably dangerous. A “risk benefit analysis” is used to determine whether safer/less expensive alternative designs were available to the manufacturer.
Federal regulations set minimum standards for the design of many consumer products, and preemption defenses may preclude liability in some situations if the manufacturer follows and obtains federal approval for a product. Automotive recalls and product liability cases are usually a result of a defective design.
(3) Failure to warn or inadequate warning or instruction associated with the product:
All consumer products come with necessary and appropriate warnings and instructions for use. If the lack of a warning makes the product and use of the product unsafe, the manufacturer is liable for the failure to place the warning.
(4) Misrepresentation:
The product fails to conform to a representation or warranty. Warranty claims are more common in commercial and economic loss cases than in personal injury cases. In many States, The Product Liability Act does not apply to cases with only economic loss, because the Commercial Code provides recourse for breach of warranty.
The warranty may be written or implied based upon the products intended purpose and merchantability. An example of a breach of warranty cases are cases involving automotive defects.
Child car seats commonly expire between 6 and 10 years from the manufacture date due to wear and tear, changing safety regulations, recalls, and the limits of manufacturer testing.
All children whose weight or height exceeds the specified limit for their car safety seat should use a booster seat until the vehicle seat belt fits properly.
Compensation encompasses medical expenses (past and future), lost earning capacity if injuries cause permanent disability, pain and suffering, emotional distress, loss of enjoyment of life, and punitive damages when manufacturer conduct was particularly reckless. Family members may also recover for their own suffering and loss of their child’s society.
Even without physical injuries, near-miss incidents may support claims, particularly if they reveal defects affecting many units. Reporting these failures helps identify dangerous products and may contribute to recalls protecting other children.
The Catastrophic Consequences of Equipment Failure
Car seat defects don’t result in minor inconveniences—they cause life-altering injuries to the most vulnerable passengers. Traumatic brain injuries from heads striking interior surfaces. Spinal damage from improper restraint positioning. Internal injuries from chest clip failures. Strangulation from twisted harnesses. Burns from materials that ignite during post-crash fires.
Families confront overwhelming medical expenses, ongoing therapy costs, adaptive equipment needs, and home modifications. Many injured children face permanent disabilities requiring lifetime care. Parents must abandon careers to provide constant supervision. Siblings experience trauma from witnessing their brother or sister’s suffering.
Lyon Firm Auto Defect Settlements
Joe Lyon has over 20 years of experience representing plaintiffs in catastrophic injury and wrongful death defective product cases.
The Firm is capable of reviewing the dangers and litigating a case involving virtually any product.
The Firm has handled defective product cases involving defective cars, defective motorcycles, and auto components.
The Firm handles cases on contingency fees advancing all costs of the case and accepts the financial risk of the litigation to allow the clients access to court and reduce the financial stress while they focus on their healthcare needs.
The Firm does not seek reimbursement for fees or costs in the event of a non-recovery.
$ Confidential
GEN III Chrysler Seat Belt Buckle: 1995 Chrysler Mini Van. Alleged Seat Belt Buckle Inadvertent Release.
(Mansfield, Ohio) Joseph M. Lyon, along with co-counsel, his father, Michael F. Lyon, litigated and resolved a case on behalf of a 14-year-old boy from Mansfield, Ohio who suffered a frontal lobe brain injury and facial deformity following an auto accident where it was alleged the Gen III seat belt buckle in the 1995 Chrysler Mini Van failed to restrain him.
Specifically, evidence was presented that the seat belt buckle was defectively designed to inadvertently release during foreseeable accident sequences, and therefore the buckle design created a heightened risk of false latching.
Mr. Lyon argued that the company knew of the alleged defect yet failed to adequately warn or recall the seat belt buckle. After two years of litigation, the parties reached a confidential settlement two weeks before trial for that will provide the care and security for the minor child for the rest of his life. Chrysler denied any wrongdoing.
$ Confidential
General Motors/ Takata: 2000 Pontiac Grand AM: Lap Belt Only:
(Pikeville, KY): The Lyon Firm was lead counsel in a confidential settlement on behalf of a 19 year old female who suffered a severe spinal cord injury in a frontal collision where she was restrained with only a lap belt.
Unfortunately, the accident victim was without the benefit of a shoulder harness, and resulted in her suffering a permanent injury that left her as a paraplegic.
The litigation started 8 months after the accident and involved extensive document production and depositions, all related to the lack of testing and the design of the lap belt. Every other passenger walked away from the scene who had the benefit of the shoulder harness.
Fortunately, these very dangerous seat belt designs are no longer placed in current automobiles, but lap belt only seat belts remain in many older cars.
Product Liability Information Center
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