Abstract:
The present invention provides a buckle and tongue combination for restraining an occupant in a seat, the buckle and tongue combination. The combination includes a housing, a frame located within the housing, two pawls disposed upon the frame, each pawl having a distal end and a proximal end, each distal end having a release abutment extending from the respective pawl, a hinge pin disposed at the proximal end of each pawl for pivotally coupling the pawls to the frame, a tongue adapted to be disposed adjacent the two pawls, the tongue interlockingly engages the pawls, a biasing member disposed within the housing, the biasing member engages the pawls urging the pawls to a locked position with respect to the adjacent tongue and a release button slidably secured along the frame, the release button biased in a first or locked position, the release button having at least one inclined abutment surface which engages the release abutments and urges the two pawls towards an unlocked position when the release button is urged toward a second position opposite from the first position, whereby the user is able to release the tongue from the buckle upon depressing the release button toward the second or unlocked position. 
     In one embodiment, the tongues include a molded portion and an alignment key so as to assure proper orientation of the tongue with the housing. In addition, the housing includes an ejector contact pad which acts against the alignment key to eject the tongues. The contact pad is finished so as to provide an aesthetic appearance. In another embodiment, the tongue may comprise a single tongue rather than dual tongues. Still further, another embodiment provides overlapping tongues wherein a first tongue includes a pawl spreader and a second tongue includes a pawl lock.

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
     This application claims the benefit of U.S. Provisional Application No. 60/486,631, filed Jul. 11, 2003. 
    
    
     FIELD OF THE INVENTION 
     The invention relates generally to safety restraints systems and, in particular, buckle and tongue combinations for safety restraints in vehicle child seats. 
     BACKGROUND OF THE INVENTION 
     The prior art safety restraint systems include combination buckle and tongue devices incorporated in a belt or webbing system to safely secure an individual or occupant in a seat. The buckle supplies the necessary attachment portions so that a five-point or three-point restraint can be used. The terms “three-point” and “five-point” refer to the number of anchorage points built into the restraint system. For example, in a five-point restraint, anchorage points are located as follows: one for each shoulder, one in front of the crotch, and one on each side of the hips. Webbing is placed through eyelet holes at each seat anchorage point and through the three web slots on the buckle device. 
     U.S. Pat. No. 3,262,169 discloses a buckle assembly having a single tongue with dual pawls. The pawls are released via a cover lever which pivots about hinge point so that a driving portion engages actuating arms to pivot locking dogs out of engagement with the tongue. U.S. Pat. No. 4,809,409 discloses a belt lock for safety belt systems having split or dual tongues with side notches. U.S. Pat. No. 6,619,753 discloses a car seat having a buckle in a five point restraint system. 
     The prior art systems suffer disadvantages. For instances, the prior art can be cumbersome to use, and lack a positive lock acknowledgement. The prior art systems are expensive to manufacture and are bulky. 
     SUMMARY OF THE INVENTION 
     The present invention provides a buckle and tongue combination for restraining an occupant in a seat, the buckle and tongue combination. The combination includes a housing, a frame located within the housing, two pawls disposed upon the frame, each pawl having a distal end and a proximal end, each distal end having a release abutment extending from the respective pawl, a hinge pin disposed at the proximal end of each pawl for pivotally coupling the pawls to the frame, a tongue adapted to be disposed adjacent the two pawls, the tongue interlockingly engages the pawls, a biasing member disposed within the housing, the biasing member engages the pawls urging the pawls to a locked position with respect to the adjacent tongue and a release button slidably secured along the frame, the release button biased in a first or locked position, the release button having at least one inclined abutment surface which engages the release abutments and urges the two pawls towards an unlocked position when the release button is urged toward a second position opposite from the first position, whereby the user is able to release the tongue from the buckle upon depressing the release button toward the second or unlocked position. 
     In one embodiment, the tongues include a molded portion and an alignment key so as to assure proper orientation of the tongue with the housing. In addition, the housing includes an ejector contact pad which acts against the alignment key to eject the tongues. The contact pad is finished so as to provide an aesthetic appearance. In another embodiment, the tongue may comprise a single tongue rather than dual tongues. Still further, another embodiment provides overlapping tongues wherein a first tongue includes a pawl spreader and a second tongue includes a pawl lock. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a perspective view of a buckle and dual tongue combination in accordance with the present invention. 
         FIG. 2  is a partial view of the buckle and dual tongue of  FIG. 1 . 
         FIG. 3  is a back view of the buckle and dual tongue combination shown in  FIG. 2 . 
         FIG. 4  is a view of the buckle and dual tongue combination of  FIG. 3 , but with the back frame half omitted. 
         FIG. 5  is a partial perspective, partial exploded view of one frame half and a separator. 
         FIG. 6  is a view of the release button and pawl configuration shown in  FIG. 4 , but with the tongue and frame omitted. 
         FIG. 7  is a perspective view of a tongue as used in an alternative embodiment of the present invention. 
         FIG. 8  is a front view of the dual tongue and back housing portion of the housing shown in  FIG. 1 . 
         FIG. 9  is a back view of the dual tongue and back housing portion of  FIG. 8 . 
         FIG. 10  is a view of an overlapping tongue embodiment in accordance with another embodiment of the present invention. 
         FIG. 11  is a view of the tongue shown in  FIG. 10  arranged in overlapping configuration for insertion into a buckle. 
         FIGS. 12 and 13  are a partial cross sectional, partial side view of a pawl pin extending through an opening in a pawl, and a perspective view of the pawl, respectively. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       FIG. 1  shows a perspective view of a buckle  10  and dual tongue  12  combination in accordance with a preferred embodiment in the present invention. The buckle  10  is shown to include a housing  14  having a front housing portion  16  and a back housing portion  18 . An opening  20  is provided in the front housing portion  16  and allows access to a release button  22 . The top of the housing includes tongue openings  24  which receive the respective first and second tongues  26 ,  28 . Each tongue  26 ,  28  includes a molded belt slot portion  30 ,  32 . 
       FIG. 2  is a partial view of the buckle  10  and dual tongue  12  shown in  FIG. 1 . However, the molded belt slot portions  30 ,  32  have been omitted for sake of illustration, as well as the housing  14 .  FIG. 2  better illustrates the release button  22 , and also shows the release button springs  34 . With the molded belt slot portion  30 , 32  omitted,  FIG. 2  readily shows the depending portion  36  extending from the respective tongue  26 ,  28 . The depending portion  36  includes the belt slot  38 . A belt (not shown) extending from a chest harness (not shown) may extend through the belt slot  38  of the depending portion  36  of the tongues  26 ,  28 . A portion of a frame  40  is also shown including the front frame half  42 . The back frame half  44  can be seen in  FIG. 3 . The frame  40  includes a belt slot  46  for receiving webbing or other type of belt (not shown) so as to provide a crotch anchoring of the buckle  10 . 
       FIG. 3  is a partial back view of the buckle  10  and dual tongue  12  combination shown in  FIG. 2 . The back frame half  44  is clearly shown, as well as a portion of the front frame half  42 . The front and back frame halves  42 ,  44  are identical components. Each frame half  42 ,  44  includes a substantially planar or main body portion  48  having a tongue receiving neck portion  50  with a left side  52  and a right side  54 . The main body portion  48  also includes a left shoulder portion  56  and right shoulder portion  58 , with each shoulder portion having an arcuate shaped pawl release pin slot  60 . A lower portion  62  of the main body portion  48  includes a left side  64  and a right side  66 . The lower portion  62  includes a left and right pawl hinge pin recess  68 ,  70 . The neck portion  50  also includes a separator slot  72  extending longitudinally along a center line of the neck portion  50 . A pawl release pin  74  is shown to be received by each arcuate shaped pawl release pin slot  60 . A hinge pin  76  is shown to be received by each hinge pin recess  68 ,  70 . 
       FIG. 4  is a partial view of the buckle  10  and dual tongue  12  combination of  FIG. 3 , but with the back frame half  44  omitted and exposing the front frame half  42 . Most apparent in  FIG. 4  is the left and right pawls  78 ,  80 . Each pawl  78 ,  80  includes a distal end  82  and a proximal end  84 . Each proximal end  84  includes a hole  86  to receive and retain a hinge pin  76 . The distal ends  82  each include a hole  88  to receive and retain a pawl release pin  74 . The proximal end  84  of the pawls  78 ,  80  also include a spring retainer  90  which includes a recessed area  92  formed by an over hanging flange portion  94 . A pawl spring  96  is trapped between the spring retainer  90  and the opposing inner walls  98  of the frame halves  42 ,  44 . A coil spring is shown but other embodiments are possible such as a bent metal plate spring. A bend portion  100  is shown in the front frame half  42  which offsets the plane of a belt slot portion  102  inwardly from the plane of the main body portion  48  of the frame  40 . In this manner, the opposing belt slot portions  102  from each frame half  42 ,  44  come into facing contact with one another and the main body portions  48  are thus spaced apart to accommodate the pawls  78 ,  80 . 
     Each pawl  78 ,  80  includes a hook portion  104  which is formed by a curved portion  106  having a pawl spreading engagement wall  108  which in the locked position of  FIG. 4  extends at a substantially 45 degree angle with respect to the longitudinal axis of the respective tongue  26 ,  28 . The pawl spreading engagement wall  108  extends into a first longitudinally extending wall  110 . A pawl ledge  112  is located between the first longitudinally extending wall  110  and a second longitudinally extending wall  114 . Each pawl  78 ,  80  further includes an abutment wall  116 .  FIG. 4  shows that the pawl ledges  112  have a mild reverse angle such that the pawl ledges  112  extend in a converging manner in a direction downward as viewed from  FIG. 4 . 
     Each of the tongues  26 ,  28  of  FIG. 4  are shown to include a pawl spreader wall  120 , a first and second longitudinally extending wall  122 ,  124 , an abutment wall  126 , and a tongue ledge  128 . The tongue ledge  128  extends in an angle, as viewed in  FIG. 4 , in a manner similar to the pawl ledges  112 . A longitudinally extending separator plate  130  is shown to be located between the dual tongues  26 ,  28 . 
       FIG. 5  is a perspective exploded view of one of the frame halves  42 ,  44  and the separator plate  130 . As noted above, the first and second frame halves  42 ,  44  are identical. One of the sides of the neck portion  50  includes a flange portion  132  extending from the main body portion  48  at a right angle and in a plane parallel to a tongue path. The flange portion  132  includes two tabs  134  extending outwardly from the flange portion  132 . The other side of the neck portion  50  includes a slot  136  adapted to receive the neck flange portion  132  from the mating frame half. The lower portion  62  of the main body portion  48  includes a flange portion  132  extending from the main body portion  48  at a right angle and in a plane parallel to a tongue path. The flange portion  132  also includes two tabs  134  extending from the flange portion  132 . The other side of the lower portion  62  includes a slot  136  for receiving a flange portion  132  from a mating frame half  42 ,  44 . The pawl hinge pin recesses  68 ,  70  are shown to be formed by a deformed tab  138  displaced from a plane of the main body portion  48 . The longitudinal separator slot  72  is shown to extend along a center line of the neck portion  50 . The separator plate  130  is shown to include a main body portion  140  with tabs  142  extending from both ends. The separator plate  130  is received by the separator slot  72  and is prevented from passing through the slot  72  by means of the end tabs  142 . The separator plate  130  is necessary for the dual tongue embodiment of  FIG. 4  because it counters the force applied by each pawl. Without the plate  130 , the two pawls would squeeze the tongue slightly but the tongue would still be free to wiggle in the neck portion and possible escape from the buckle prematurely. The frame  40  further includes a hole  144  for securing the frame  40  to the housing  14 . 
     It will be appreciated that when the first and second frame halves  42 , 44  are assembled, the flange portion  132  extending from the neck portion  50  of one frame half is received by the slot  136  formed in the neck portion of the other frame half. Therefore, the tabs  134  of the flange portion  132  may be deformed or displaced so as to prevent the flange portion  132  from being withdrawn from the respective slot  136 . In a similar manner, the lower flange portions  132  are received and secured by the respective lower slot  136  of the mating frame half. The flange portions  132  include a shoulder  146  having a width wider than the width of the slots  136 . The shoulder  146  therefore engages the inner wall of the mating frame half in an abutting manner and defines, together the mating belt slot portions  30 ,  32 , the dimensions of the interior space or compartment between the frame halves  42 ,  44 . The frame may also include holes for restraint of the various springs disclosed herein. Alternatively to that disclosed herein, the pawl, release pin and hinge pin may be a unitary cast metal. 
       FIG. 6  is a view of the release button  22  and pawl configuration shown in  FIG. 5 , but with the tongue  12  and frame  40  omitted. The release button  22  is adapted for movement between the upper or locked position shown in  FIG. 6  with respect to the hinge pins  76  in a lower or unlocked position. The release button springs  34  urge the release button  22  towards the upper or locked position shown in  FIG. 6 . The release button  22  includes two recesses  150 . Each recess  150  includes an inclined ramp surface  152  and a longitudinally extending delay wall  154  which extends substantially in the direction of a path the release button  22  moves between the locked and unlocked positions. The recesses  150  each include a stop or abutment wall  156  which extends from the delay wall  154  and together with the inclined ramp surface  152  forms a recess opening  158  which opens outwardly from the release button  22 . Similar to  FIG. 4 , the pawls of  FIG. 6  are shown in the locking engagement wherein the distal ends of the pawls  78 ,  80  have rotated about the hinge pins  76  toward one another. 
       FIG. 7  shows an alternative embodiment of the present invention wherein the dual tongues  26 ,  28  are replaced by a single tongue  160  configuration. The single tongue  160  of  FIG. 7  includes a wedge shaped pawl separator  162  at a distal end  164 . Tongue ledges  166  are also provided. The proximal end  168  of the tongue  160  includes a single belt slot  170 . However, it will be readily apparent that other configurations are possible for receiving a belt or webbing (not shown). In the alternative embodiment of  FIG. 7 , the same components as shown in  FIG. 4  may be used, including the frame halves  42 ,  44 . However, in the embodiment of  FIG. 7 , the separator plate  130  is omitted so as to accommodate the single tongue  160 . 
       FIG. 8  shows a front view of the back housing portion  18  and the dual tongues  26 ,  28 . The inner face  172  of the back housing portion  18  includes ejector springs  174  having a first end  176  and a second end  178 . Ejector guides  180  are provided and include first opposing inner wall faces  182  having a dimension at the first end  176  of the spring  174  which closely conforms to the diameter of the spring  174 . The ejector guide  180  further provides second opposing inner wall faces  184  at the second end  178  of the spring  174  which has a greater width than the first inner wall faces  182 . The tongue openings  24  are also shown as well adjacent ejector pads or contact surfaces  186 . The ejector pads  186  have a stem portion  188  extending into the second end  178  of the respective springs  174 .  FIG. 9  is a back view of the back housing portion  18  and dual tongue of  FIG. 8 .  FIG. 9  shows the alignment pin  190  which extends from the molded belt slot portion  30 ,  32  of the respective tongue  26 ,  28 . The alignment pin  190  is arranged as to come into contact with the ejector pad  186 . In addition, the alignment pin  190  has a half moon configuration so as to conform with the alignment recess  192  ( FIG. 1 ) which extends from the tongue openings  24 . In order for the alignment pin  190  to be inserted into the housing  14 , the tongue must be oriented correctly with respect to the housing  14 . The back housing portion  18  is shown to include a cut out portion  194  so as to accommodate assembly of a belt (not shown) to the belt slot  46 . The inner face of the back housing portion  18  also includes stems  196  for fastening the frame to the housing  14  via the hole  144  located at the neck portion  50 . The inner face of the back housing portion  18  also includes raised portions  198  for positioning the frame  40  within the housing  14 . The front housing portion  16  has similar configurations so as to maintain the frame  40  within the housing  14 . 
       FIG. 10  is a view of a tongue  200  in accordance with yet a further embodiment of the present invention.  FIG. 10  discloses overlapping tongue embodiment and includes a pawl spreader tongue  202  and a pawl lock tongue  204 . The pawl spreader tongue  202  includes a proximal end  206  having a depending portion  208  having a belt slot  210 . The proximal end  206  further includes a locking slot  212 . The distal end  214  of the tongue  202  includes a pawl spreader  216  having an end  218  which is substantially curved. In one alternative embodiment, the pawl spreader  216  may include a distal end  218  which presents a spade like shaped configuration. For example, the pawl separator  216  may include a distal end  218  having a mid section portion (not shown) which is perpendicular to the longitudinal axis of the tongue, and outer edge portions (not shown) on either side of the mid section portion, wherein the outer edge portions converge towards the distal end  218  of the tongue  202 . The pawl spreader tongue  202  further includes lateral edges  220 , the lateral edges  220  each include a clearance notched area  222 . The clearance notched areas  222  present an edge  224  which diverge from one another towards the distal end  214  of the tongue  202 . 
     The pawl locking tongue  204  includes a proximal end  226  and a distal end  228 . A depending portion  230  extends from the proximal end  226  and includes a belt slot  232 . The proximal end  226  also includes a locking tab  234 . The distal end  228  includes a substantially flat edge  236  which extends substantially perpendicular to a longitudinal axis of the tongue  204 . The pawl locking tongue  204  further includes lateral edges  238 . The lateral edges  238  include tongue ledges  240  which are formed by a notch  242  in the lateral edge  238 . The tongue ledges  240  extend substantially in a direction perpendicular to the longitudinal axis of the tongue  204 . 
       FIG. 11  shows the pawl spreader tongue  202  placed over the pawl lock tongue  204  in interlocking engagement via the tab  234  extending through the slot  212 . It will be appreciated that the pawl spreader  216  extends beyond the flat edge  236  so that the pawl spreader  216  is presented to the pawls  78 ,  80  upon insertion of the interlocking tongues  202 ,  204  into a buckle  10 . Further, it can be seen that the clearance notch area  222  of the pawl spreader tongue  202  and the notches  242  of the pawl lock tongue  204  expose the tongue ledges  240  so that the interlocking tongues  202 ,  204  may be locked with the ledges  112  of the pawls  78 ,  80 . It will be appreciated that the insertion of only the pawl lock tongue  204  into the buckle  10  will cause the flat edge  236  to come into abutment with the distal ends  82  of the pawls  78 ,  80  and will not spread the pawls  78 ,  80  due to the flat edge  236  presented to the distal end  82  of the pawls. The pawl spreader tongue  202  is required in order to spread the pawls  78 ,  80  apart and allow complete entry of the tongue. Similarly, while the pawl spreader  216  may be inserted into the buckle  10  without the pawl lock tongue  204 , due to the sloping edges  224  of the pawl spreader  216  which do not present the locking ledges as in the pawl lock tongue  204 , the pawl spreader  216  alone is incapable of being locked within the buckle  10 . This feature prevents the intervertent securement of a single tongue  202 ,  204  within a buckle  10 . 
       FIG. 12  shows a partial cross sectional partial side view of a pawl pin  250  extending through an opening  252  in a metal part  254 , such as a pawl.  FIG. 13  is a perspective view of the pawl pin  250 . The pawl opening  252  was formed via a stamped process. The desired opening diameter  256  is shown on the left. As an unintended consequence of the stamping process, the diameter of the opening increases towards the right side in a conical fashion to a maximum diameter  258 . Insertion into a stamped opening in a pawl or other metal part results in the pin having an interference fit with the opening on the left side but without an interference fit with the opening on the right side in the area of the conical opening. As a result, undue stress may be imposed upon the pin causing flexing and premature breakage of the pin. This is true regardless of whether the pin is made of metal or plastic. However, the plastic pins are more susceptible to premature breakage. The pin  250  of  FIG. 12  presents a central tubular portion  260  having a substantially constant diameter which provides an interference fit  262  with the opening. The length of the central tubular portion  260  is longer than the length of the opening  252 . End portions  264  provide a diameter which is smaller than the diameter of the opening  252  so as to avoid an interference fit. The end portions  264  include the smaller reduced diameter cylindrical end  266  as well as the tapered or transition portion  268  which extends from the central tubular portion  260 . Ribs  270  are located about the central tubular portion  260 . The ribs  270  have a length substantially shorter than the length of the portion  260 . The ribs  270  extend in a longitudinal direction but arranged about the perimeter of the central tubular portion  260  and adjacent each of the end portions  264 , defining first and second rib areas  272 ,  274 . The diameter defined by each of the first and second rib areas  272 ,  274  is capable of providing an interference fit  276  within the conical shaped open area of the opening. Yet, the ribs  270  may be deformed so as to allow insertion into the opening  252 . Upon assembly,  FIG. 12  discloses that the central tubular portion  260  provides an interference fit  262 . In addition, the ribs of the second rib area provide an interference fit  276 . 
     The operation of the buckle and tongue combination is relatively straightforward. To lock the tongue to the buckle, the user inserts the tongue into the neck portion of the buckle. The tongue will engage the pawls and spread the pawls apart so as to cause the pawls to rotate about the hinge points. The rotation of the pawls will move the release pins in a direction generally outwardly. The release pins will act upon the release button so as to move the release button downwardly with respect to the housing and frame. The downward movement of the release button will load the release button spring. Upon the distal end of the tongue clearing the hook portion of the pawls, the pawls will close upon the tongue with the pawl ledges coming into locking engagement with the tongue ledges. The rotation of the pawls toward the tongue is a result of the pawl spring and release button springs unloading the compressive forces. The release button does not need to be actuated by the user during coupling of the tongue with the buckle. In order to release the tongue from the buckle, the user presses the release button in a downward direction. When the user pushes the release button in the downward direction, the effective spacing between the pawl release pins increases as a result of the ramp surface acting upon the release pins. At the same time, the release button springs and pawl spring are compressed and loaded with a compressive force. As the pawl ledges disengage from the tongue ledges, the compressive load stored in the ejection springs urge the contact pad outwardly from the housing. The contact pad similarly urges the alignment pins and consequently the tongues outwardly from the housing such that they will not reengage with the pawls upon release of the release button. As soon as the tongue clears the hook portion of the pawls, the loaded compressive force of the pawl spring and release button spring will urge the pawls to rotate back to a closed position and urge the release button upward to a locked position. The function of the contact pad is to act as a style feature or protective cover for the internal mechanism. The function of the Ejector Guide is to allow the contact pad to move vertically and remain aligned with the spring and the cover. Without this feature, the user has to use two hands to operate the device. One hand is used to push and hold the Release Button, and the other hand is used to pull the tongues out of the buckle. Users in the market would prefer to only use one hand to release the buckle.