Abstract:
A connector is provided to connect criss-crossing shoulder straps on a body-engaging harness. The connector joins overlapping portions of the shoulder straps while maintaining discrete portions thereof spaced apart. A preferred embodiment of the connector is a unitary piece of rigid plastic having slots formed therein to receive portions of the shoulder straps.

Description:
This application is a continuation of U.S. Ser. No. 09/084, 030 filed on May 22, 1998, now abandoned. 
    
    
     FIELD OF THE INVENTION 
     The present invention relates to methods and apparatus for interconnecting criss-crossing straps on a safety harness. 
     BACKGROUND OF THE INVENTION 
     Various occupations place people in precarious positions at relatively high heights, thereby creating a need for fall-arresting safety apparatus. Such apparatus requires a reliable lifeline and reliable connections with both a support structure and the person working in proximity to the support structure. U.S. Pat. No. 5,203,829 to Fisk et al. discloses a body-engaging harness suitable for this purpose. As disclosed in the Fisk et al. patent and shown herein in FIGS. 5-6, the Fisk et al. harness  10  generally includes a shoulder strap  12 , a waist strap  14 , and a seat strap  16 . 
     The shoulder strap  12  includes left and right shoulder strap segments  18  and  20  which pass over respective shoulders of a person. A first end portion of the left shoulder strap segment  18  is fixedly secured to an adjustment member  22  by means of stitching  42 . The left shoulder strap segment  18  extends from the adjustment member  22 , across a back pad  30  and then into interlaced engagement with a first intermediate portion  26  of the seat strap  16 . A second end portion  24  of the left shoulder strap segment  18  extends beyond the juncture with the seat strap  16  and is fixedly secured to a female buckle connector  58 . 
     A first end portion of the right shoulder strap segment  20  is adjustably secured to the adjustment member  22  and thereby connected to the first end portion of the left shoulder strap segment  18 . A distal end  25  of the first end portion of the right shoulder strap segment  20  is folded and sewn against itself to discourage removal from the adjustment member  22 . The distal end  25  is retained relative to an intermediate portion of the right shoulder strap segment  20  by means of a keeper  70 . The intermediate portion of the right shoulder strap segment  20  extends from the adjustment member  22 , through a front slide assembly  34 , which includes both a D-ring and an adjuster link, and then across the back pad  30 . The right shoulder strap segment  20  extends from the back pad  30  into interlaced engagement with a second intermediate portion  38  of the seat strap  16 . A second end portion  36  of the right shoulder strap segment  20  extends beyond the juncture with the seat strap  16  and is fixedly secured to a female buckle connector  58 . 
     The back pad  30  cooperates with a D-ring  29  to define a suspension assembly  28 . The strap segments  18  and  20  are connected to the back pad  30  by heavy duty stitching  32 , and the D-ring  29  is secured to the back pad  30  by webbing extending between discrete sections of the stitching  32 . The resulting suspension assembly  28  provides an anchorage point for a fall arrest line and also encourages proper use of the harness by giving it shape which suggests how to correctly secure the harness about a person. 
     A first end portion  15  of the waist strap  14  is fixedly secured to the seat strap  16 , proximate the second intermediate portion  38  thereof. An intermediate portion of the waist strap  14  passes through the front slide assembly  34 . A second end portion of the waist strap  14  is connected to a male buckle connector  56 . An adjustment assembly  60  is provided on the second end portion of the waist strap  14  to facilitate adjustments to the length of the waist strap  14 . The harness  10  may be further adjusted by moving the adjuster link on the front slide assembly  34  away from the D-ring along the right shoulder strap segment  20  and the waist strap  14 ; repositioning the right shoulder strap segment  20  and the waist strap  14  relative to respective portions of the D-ring; and moving the adjuster link back toward the D-ring. 
     As noted above, the first intermediate portion  26  of the seat strap  16  is interlaced with the left shoulder strap segment  18 . A female buckle connecter  58  is connected to a distal end of this first intermediate portion  26 . A central portion of the seat strap  16  extends between the intermediate portions  26  and  38 , and each end portion of the seat strap  16  defines a respective leg strap segment  64  or  66 . Spacing tabs  62  are sewn to portions of the seat strap  16  to ensure proper positioning of the leg portions  64  and  66  relative to a person&#39;s legs. 
     A male buckle connector  56  is disposed on each leg portion  64  or  66  before a distal end  65  or  67  of each is folded and sewn against itself to discourage removal of the connector  56 . The effective lengths of the leg portions  64  and  66  may be adjusted by repositioning the buckles  56  relative thereto. The distal ends  65  and  67  are retained relative to intermediate portions of respective straps  64  and  66  by means of additional keepers  70 . The buckle connectors  56  on the leg portions  64  and  66  selectively interlock with the buckle connectors  58  on the ends of respective shoulder strap segments  18  and  20 . 
     Another conventional body-engaging harness is known in the art as a “vest-type” harness. This prior art harness has shoulder straps which criss-cross across a person&#39;s back (between the waist and the shoulders) and extend parallel to one another across a person&#39;s chest (between the shoulders and the waist). A transverse strap extends laterally across the person&#39;s chest between the two parallel strap portions. Some of these harnesses include another transverse strap which extends between the two criss-crossing strap portions, about eight inches below the dorsal connection point. This additional strap is intended to reduce the likelihood of a person falling out of the harness during a fall arrest. Unfortunately, such an arrangement also impedes adjustability of the harness and/or does not maintain a fixed distance between the additional strap and the dorsal connection point. 
     An object of the present invention is to provide an improved suspension assembly for body-engaging harnesses. Another object of the present invention is to provide an improved method of interconnecting criss-crossing straps on a body-engaging harness. 
     SUMMARY OF THE INVENTION 
     The present invention provides methods and apparatus which facilitate interconnection of criss-crossing harness straps. In a preferred embodiment and/or mode of operation, a triangular connector guides a first strap in a first direction and a second strap in a second direction. Intermediate portions of the straps extend between connection points on the connector and cooperate therewith to retain a D-ring. The arrangement eliminates the need for heavy duty stitching that was otherwise required with the prior art back pad and thereby provides a suspension assembly which is easier and less expensive to manufacture. The arrangement also provides a laterally extending support at a fixed distance beneath the D-ring to span the downwardly widening gap defined between the shoulder straps. Additional features and/or advantages of the present invention may become more apparent from the detailed description which follows. 
    
    
     BRIEF DESCRIPTION OF THE DRAWING 
     With reference to the Figures of the Drawing, wherein like numerals represent like parts and assemblies throughout the several views, 
     FIG. 1 is a plan view of a connector constructed according to the principles of the present invention; 
     FIG. 2 is a rear view of a harness configured according to the principles of the present invention; 
     FIG. 3 is a plan view of the connector of FIG.  1  and shoulder strap portions of the harness of FIG. 2; 
     FIG. 4 is a plan view of the connector of FIG. 1 secured to shoulder strap portions of another harness; 
     FIG. 5 is a front view of a prior art harness; and 
     FIG. 6 is a rear view of the prior art harness of FIG.  5 . 
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
     A preferred embodiment connector constructed according to the principles of the present invention is designated as  100  in FIGS. 1-4. The connector  100  is an injection molded piece of plastic having a polyethylene to vinyl ratio of approximately four to one. The connector  100  may be described as a substantially triangular, rigid member having three vertices or connection regions  101 ,  102 , and  104 , and three sides  120 ,  140 , and  160 . The term “vertex” is used to describe each of three discrete portions which cooperates with the other portions to define a single plane. 
     As shown in FIGS. 1-3, the first vertex or connecting region  101  is configured to receive and interconnect criss-crossing shoulder straps  212  and  214 . A first slot  112  is formed in the vertex  101  to receive the strap  212  extending in a first direction. A second slot  114  is formed in the vertex  101  to receive the strap  214  extending in a second direction. Relatively larger, parallel slots  117  and  119  are provided just below the vertex  101  to receive both straps  212  and  214 , and to retain a D-ring  230  between the connector  100  and the straps  212  and  214 . 
     The first side  120  of the connector  100  is configured to guide the first strap  212  in a first direction away from the vertex  101 . Slots  122  and  124  are formed in the first side  120  to accommodate discrete portions of the first strap  212 . A depression or recess  126  is formed in the first side  120  to accommodate the length and thickness of a portion  212   c  of the first strap  212  disposed between the slots  122  and  124 . An opening  128  is formed through the first side  120 , within the perimeter of the depression  126 , for reasons explained below. 
     The second side  140  of the connector  100  is configured to guide the second strap  214  in a second direction away from the vertex  101 . Slots  142  and  144  are formed in the second side  140  to accommodate discrete portions of the second strap  214 . A depression or recess  146  is formed in the second side  140  to accommodate the length and thickness of a portion  214   c  of the first strap  214  disposed between the slots  142  and  144 . An opening  148  is formed through the second side  140 , within the perimeter of the depression  146 , for reasons explained below. 
     The third vertex or connecting region  104  is configured to receive and support the second strap  214  and allow same to extend uninterrupted in the second direction. A slot  154  is formed in the third vertex  104  and cooperates with the slot  114  in the first vertex  101  (and the slots  142  and  144  in the second side  140 ) to guide the second strap  214  in the second direction. Similarly, the second vertex or connecting region  102  is configured to receive and support the first strap  212  and allow same to extend uninterrupted in the first direction. A slot  152  is formed in the second vertex  102  and cooperates with the slot  112  in the first vertex  101  (and the slots  122  and  124  in the first side  120 ) to guide the first strap  212  in the first direction. 
     The third side  160  spans or extends between the second and third vertices  102  and  104  and cooperates with the other sides  120  and  140  to define a triangular opening  170 . A company name  166  or some other indication may be provided on the third side  160  to indicate how the connector  100  should be oriented when the harness is being worn properly. The third side  160  may also be described as a means for spanning the lower end of the opening  170  at a fixed distance beneath the first vertex  101  and/or the D-ring  230 , and/or as a means for limiting or reducing the opening between the strap segments  212   c  and  212   d  and the strap segments  214   c  and  214   d.    
     Since the connector  100  is rigid, no one side of the connector is absolutely necessary to practice the present invention. For example, the connector may be modified in a manner which eliminates the first side or the second side (recognizing that structural integrity issues may result from such a change). 
     The preferred embodiment  100  is generally symmetrical about a center line drawn perpendicularly through the third side  160  and the slots  117  and  119 . The slots  112  and  152  are approximately eleven inches apart, as are the slots  114  and  154 . A line drawn perpendicular to the slots  112  and  152  defines an angle of approximately fifty-five degrees relative to a line drawn perpendicular to the slots  114  and  154 . 
     FIG. 3 shows how the harness straps  212  and  214  and the D-ring  230  are preferably connected to the connector  100 . First strap portions  212   a  and  214   a  extend upward away from the first vertex  101  and in divergent fashion (away from one another) toward a person&#39;s shoulders. Second strap portions  212   b  and  214   b  are disposed between slots  117  and  119  and cooperate with the connector  100  to retain the D-ring  230  therebetween. The third strap portions  212   c  and  214   c  are disposed between respective slots  122  and  124  and  142  and  144 , just inside the perimeter of respective depressions  126  and  146 . The fourth strap portions  212   d  and  214   d  extend downward from respective vertices  102  and  104  and in divergent fashion (away from one another) toward a person&#39;s waist. 
     Another advantage of the foregoing arrangement is that no stitching is required to form the resulting suspension assembly. As a result, there is less opportunity for human error during manufacture, assembly costs are reduced, and tighter quality control is maintained. Adjustment members, like those commonly used with buckles, could be provided to encourage the connector to remain in a particular position relative to the straps. In any event, the third side  160  interconnects the straps segments  212   d  and  214   d  at a fixed position beneath the D-ring  230 . 
     FIG. 2 shows a “vest-type” harness  200  constructed according to the principles of the present invention. The harness  200  generally includes shoulder straps  212  and  214 , chest straps  242  and  244 , a seat strap  216 , and leg straps  272  and  274 . 
     The right shoulder strap  212  has a first end portion adjustably secured to a “right side” of the seat strap  216  at buckle  252 . The right shoulder strap  212  extends from the buckle  252  through the connector  100  and then into interlaced engagement with a “left side” intermediate portion  264  of the seat strap  216 . A second end portion  222  of the right shoulder strap  212  extends beyond the juncture with the seat strap  216  and is secured to a female buckle connector  258 . 
     The left shoulder strap  214  has a first end portion adjustably secured to a “left side” of the seat strap  216  at buckle  254 . The left shoulder strap  214  extends from the buckle  254  through the connector  100  and then into interlaced engagement with a “right side” intermediate portion  262  of the seat strap  216 . A second end portion  224  of the left shoulder strap  214  extends beyond the juncture with the seat strap  216  and is secured to a female buckle connector  258 . The connector  100  cooperates with a D-ring  230  to define a suspension assembly that provides an anchorage point for a fall arrest line and also contributes to the shape of the harness  200  when in a “relaxed” state. 
     The “right side” chest strap  242  is connected to the right shoulder strap  212  intermediate the buckle  252  and the connector  100 . A male buckle connector  246  is connected to a distal end of the right side chest strap  242 . The “left side” chest strap  244  is connected to the left shoulder strap  214  intermediate the buckle  254  and the connector  100 . A female buckle connector  248  is connected to a distal end of the left side chest strap  244 . The buckle connectors  246  and  248  selectively interconnect to form a continuous span of webbing across a person&#39;s chest. 
     A central portion of the seat strap  216  extends between the intermediate portions  262  and  264 , and each end portion of the seat strap  216  defines a respective leg strap segment  272  or  274 . Spacing tabs  276  are sewn to portions of the seat strap  216  to encourage proper positioning of the leg portions  272  and  274  relative to a person&#39;s legs. 
     A male buckle connector  256  is disposed on each leg portion  272  or  274  before a distal end of each is folded and sewn against itself to retain the connector  256 . The buckle connectors  256  on the leg portions  272  and  274  selectively interlock with the buckle connectors  258  on the ends of respective shoulder straps  214  and  212 , to form closed loops about a person&#39;s legs. 
     The present invention may also be described in terms of methods of making a body-engaging harness. One such method may be described in terms of inserting right and left straps through slots in a connector so that they cross over one another and extend in divergent fashion away from the common juncture. Another such method may be described in terms of guiding right and left straps in discrete directions away from a connector that joins overlapping portions thereof. Yet another method may be described in terms of forming a rigid member having at least three connection regions which are disposed in triangular fashion relative to one another; connecting a first strap to two of the connection regions; and connecting a second strap to two of the connection regions in such a manner that at least one strap is connected to each of the connection regions. 
     As suggested by FIG. 4, the foregoing method may comprise an additional step of sewing on intermediate portions of the straps which are disposed between slots on the connector. In this regard, the openings or windows  128  and  148  in the connector  100  provide sufficient space for stitching  321  and  341  to be secured to the strap portions  312   c  and  314   c,  respectively. One possible application for such stitching is to secure discrete pieces of webbing between the portions  312   c  and  314   c  and either respective portions  312   a  and  314   a  or portions  312   d  and  314   d,  in order to anchor the connector  100  in a relatively fixed position relative to the shoulder straps. The resulting harness  300  similarly retains a D-ring  230  between the connector  100  and intermediate strap portions  312   b  and  314   b.    
     Although the present invention has been described with reference to a preferred embodiment and particular methods, this disclosure will enable those skilled in the art to recognize additional embodiments and/or methods which fall within the scope of the present invention. Accordingly, the scope of the present invention should be limited only to the extent of the following claims.