Abstract:
Quick release buckles are provided that include, for example: (a) a first buckle component having an engagement end and a module receiving portion opposite the engagement end; and (b) a second buckle component having an engagement end constructed for releasable engagement with the engagement end of the first buckle component, and a module receiving portion opposite the engagement end; each of the module receiving portions being constructed for fixed engagement with any one of a plurality of different modular components. Methods of assembling buckling systems and buckle assembly systems are also provided.

Description:
BACKGROUND OF THE INVENTION 
     The invention relates to quick release buckles, and more particularly to side release buckles used to join webbing straps and other articles. 
     In applications such as backpacks and luggage, quick release buckles are used to fasten webbing straps together, allowing the buckle to be easily and quickly fastened and unfastened and, in some cases, providing adjustability of the length of the strap(s). In a backpack the quick release buckles are used, e.g., to fasten the belt of the pack around the wearer&#39;s waist, to fasten a sternum strap around the wearer&#39;s chest and, in some cases, to provide releasable, adjustable length compression straps along the sides of the pack. In luggage the buckles are used, e.g., to releasably secure a removable shoulder strap to a gym bag, duffle bag or briefcase. 
     A typical, previously known side release buckle  10  is shown in FIGS. 1 and 1A. It includes male component  12  and cooperating female component  14 . To fasten the buckle, spring arms  16  of male component  12  are inserted into opening  18  of female component  14  (arrows A in FIG.  1 ), with center guide  13  sliding into center channel  15  (see FIG. 1C) to align the male and female components. The spring arms  16  expand into release openings  20  as the buckle is closed (FIG.  1 A), with shoulder  17  of each spring arm engaging the edge  19  of the release opening. To release the buckle, the user presses the spring arms  16  together, to disengage them from release openings  20  and thereby allow the male and female components to separate (arrows B in FIG.  1 A). 
     Side release buckle  10  includes webbing receiving portion  22  for receiving a webbing strap. One or both components of the buckle may include a pair of slots  22   a ,  22   b  separated by a bar  24 , as shown on the male component in FIGS. 1 and 1A. As shown in FIG. 1D, to secure webbing strap  23 , it is threaded through slot  22   a , over the bar  24 , back through slot  22   b  and under bar  26 . The length of the strap can be adjusted by sliding the strap through the slots. If adjustability is not desired, one or both of the components may include a single slot  22   c , as shown on the female component in FIGS. 1 and 1A. This allows a webbing strap to be threaded through the slot, folded back upon itself, and stitched in place, as shown in FIG. 1B (stitching  29 ). 
     SUMMARY OF THE INVENTION 
     The present invention features quick release buckles that include a standard buckle assembly including a first buckle component and a second buckle component that is releasably engageable with the first buckle component (e.g., a male component and a female component as described above). One or both of the buckle components includes a module-receiving portion that is constructed for attachment to any one of an assortment of interchangeable modular components. The ready interchangeability of the modular components also allows a single size of standard buckle assembly to be used in many different applications, with different types and sizes of web receiving portions, and with attachment devices such as snap hooks, hex rings and webbing dividers. For example, one of the buckle components can be attached to a modular component that has a web receiving portion sized to receive a first width of webbing and the other buckle component can be attached to a modular component that has a web receiving portion sized to receive a second, different width of webbing, allowing the quick release buckle to be used to join different widths of webbing. This modularity gives designers and manufacturers of articles that use quick release buckles great flexibility, without the need to specify and stock a large number of different types of quick release buckles. The manufacturer can simply inventory a supply of a single size of standard buckle assemblies and then purchase modular components as needed for different applications. 
     In one aspect, the invention features a quick release buckle that includes: (a) a first buckle component having an engagement end and a module receiving portion opposite the engagement end; and (b) a second buckle component having an engagement end constructed for releasable engagement with the engagement end of the first buckle component and a module receiving portion opposite the engagement end. Each of the module receiving portions is constructed for fixed engagement with any one of a plurality of different modular components. 
     Preferred quick release buckles include one or more of the following features. The module receiving portions are substantially identical to each other. The first and second buckle components are side release buckle components. Each module receiving portion includes an aperture constructed to receive a male portion of a modular component in an interference engagement. The fixed engagement is permanent. 
     In another aspect, the invention features a quick release buckle system that includes: (a) a standard buckle assembly including (i) a first buckle component having an engagement end and a module receiving portion opposite the engagement end; and (ii) a second buckle component having an engagement end constructed for releasable engagement with the engagement end of the first buckle component and a module receiving portion opposite the engagement end; and (b) a plurality of modular functional components, each modular component having a first end constructed for engagement with the module receiving portion and a second, opposite fastening end, at least some of the fastening ends being different from each other. 
     Preferred quick release buckle systems include one or more of the following features. The module receiving portions are substantially identical to each other. The first and second buckle components are side release buckle components. Each module receiving portion includes an aperture constructed to receive a male portion extending from the first end of the modular component in an interference engagement. The fixed engagement is permanent. Each first end of each of the plurality of modular components is substantially identical to every other first end. The fastening end of the modular component includes a functional portion selected from the group consisting of web-receiving slots, hex rings, webbing dividers and snap hooks. 
     In yet another aspect, the invention features a quick release buckle that includes: (a) a first buckle component having an engagement end and a module receiving portion opposite the engagement end; and (b) a second buckle component having an engagement end constructed for releasable engagement with the engagement end of the first buckle component. The module receiving portion of the first buckle is constructed for fixed engagement with any one of a plurality of different modular components. 
     The invention also features methods of assembly of a buckling system. Preferred methods include: (a) providing a standardized buckle having at least one side constructed to receive a modular functional component, (b) providing a set of modular functional components having engaging structure constructed to engage the side of the standardized buckle, (c) selecting a modular functional component from the set, and (d) assembling the modular functional component with the standardized buckle. 
     Preferred methods may include one or more of the following features. Each individual member of the set of modular functional components includes a functional portion selected from the group consisting of web-receiving slots, hex rings, webbing dividers and snap hooks. The set of modular functional components includes members having different functional portions. The standardized buckle is a quick release buckle, e.g., a side release buckle. 
     In another aspect, the invention features a buckle assembly system including: (a) a supply of standardized buckles having at least one side constructed to receive a modular functional component, and (b) a supply of modular functional components, including components having different functions, each modular functional component having engaging structure constructed to engage a portion of a respective standardized buckle. 
     In preferred embodiments, the system includes one or more of the following features. The engaging structure of each modular functional component is substantially identical to the engaging structure of each other modular functional component. The standardized buckle is a quick release buckle. The supply of modular functional components includes modular functional components having a functional portion selected from the group consisting of web-receiving slots, hex rings, webbing dividers and snap hooks. 
     The term “quick release buckle”, as used herein, includes side release and center release buckles, and other buckles that include opposed, releasably engagable buckle components. 
     The term “fixed engagement”, as used herein, means engagement which does not allow any significant amount of relative rotation of the engaged parts. 
     Other features and advantages of the invention will be apparent from the following description of a presently preferred embodiment, and from the claims. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIG. 1 is an exploded view of a prior art side release buckle, in partial cross-section. 
     FIG. 1A is a plan view of the buckle of FIG. 1, in partial cross-section, showing the buckle being released by a user. 
     FIG. 1B is a perspective view of a side release buckle of the prior art joining two pieces of webbing. 
     FIG. 1C is an end view of the female portion of the prior art side release buckle. 
     FIG. 1D is a side cross-sectional view of the web-receiving portion of the male component, showing a webbing strap threaded through it. 
     FIG. 2 is an exploded view, in partial cross-section, of a quick release buckle system according to one embodiment of the invention, showing a standardized buckle assembly and a number of selectable cooperating modular components having different functions. 
     FIGS. 2A and 2B are perspective views, taken from opposite directions, showing the female portion of the standardized buckle assembly and a cooperating modular component. 
     FIGS. 3-3D are plan views, in partial cross-section, of the standardized quick release buckle of FIG. 2, assembled with selected modular components of FIG. 2, to join respective webbings of the same width. 
     FIG. 4 is a plan view, in partial cross-section, of the standardized quick release buckle assembled with selected modular components of FIG. 2 to join webbing of different widths. 
     FIG. 5 is a plan view, in partial cross-section, of the standardized quick release buckle assembled with a modular component having a webbing receiving portion and a modular component having a hex ring. 
     FIGS. 6 and 6A are plan views, in partial cross-section, of the standardized quick release buckles assembled with modular components having different types of webbing dividers. 
     FIGS. 7 and 7A are plan views, in partial cross-section, of the standardized quick release buckle assembled with modular components that have a snap hook and a webbing receiving portion, respectively. In FIG. 7A, a webbing strap including a hex ring is threaded through the webbing receiving portion. 
     FIGS. 8 and 8A are perspective views, taken from opposite directions, showing a standardized buckle component and a cooperating modular component according to an alternate embodiment of the invention. 
     FIGS. 8B and 8C are end views of, respectively, the standardized buckle female component and the modular component. 
     FIG. 8D is an enlarged end view of the modular component. 
     FIG. 8E is an end view of the standardized buckle male component. 
     FIGS. 9-9B are partial plan views showing the buckle and modular components of FIG. 8 before, during and after assembly. 
     FIGS. 10 and 10A are front and side plan views, respectively, of the buckle and modular components of FIG. 9 in their assembled state. 
    
    
     DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     A quick release buckle system according to one embodiment of the invention is shown in FIG.  2 . The system includes a standardized buckle assembly  30 , and ten selectable, different modular components  31  constructed to receive different widths of webbing  23  (shown in FIG. 2 prior to being threaded through the webbing receiving portions  22  of the modular components  31 ). Any one of these modular components  31 , as well as similar modular components constructed for other functions, can be engaged with either of the buckle components, as discussed below. 
     The standardized buckle assembly  30  includes female buckle component  32  and male buckle component  34 . Male buckle component  34  is constructed for releasable engagement with the female buckle component  32  in the manner described above with reference to FIGS. 1 and 1A, i.e. the male and female buckle components are of the “side release” type. 
     Each of the buckle components  32 ,  34 , includes a module-receiving structure  36   a ,  36   b . The two module receiving structures are identical, so that they are constructed to receive modular components that have the same engagement structure. Each module-receiving structure includes an open end  38 , opposed side walls  40 , each including a lip  42 , and a central formation  44  that defines lips  45  at the sides facing the respective side walls. 
     Each of the modular components  31  includes a pair of outer locking posts  46  and a pair of central locking posts  48 . Each outer locking post  46  includes a shoulder  50  constructed to engage lip  42  of the module receiving end, and each central locking post  48  includes shoulder  52  constructed to engage lip  45  of the central formation  44  (see FIGS.  3 - 3 D). When the locking posts of a selected module are inserted into the open end  38  of the male or female component  32  or  34  of a standardized buckle, shoulders  50  and  52  engage lips  42  and  45 , respectively, to provide a secure, permanent fixed engagement between the modular component  31  and the buckle component  32  or  34 . The provision of the set of outer and central locking posts results in a strong connection that prevents rotation of the modular component relative to the buckle component. 
     As shown in FIGS. 3-3D, the modularity of the buckle system allows a single size of standardized buckle to be used with modular components that are sized to receive a wide variety of webbing widths, e.g., from narrower than the width of the buckle (FIG. 3) to wider than the width of the buckle (FIG.  3 D). 
     As shown in FIG. 4, the modularity of the buckle system allows different widths of webbing to be joined. In the example shown in FIG. 4, a first modular component  54 , mounted on male buckle component  34 , includes two relatively wide webbing-receiving slots  56 , while a second modular component  58 , mounted on female buckle component  32 , includes a relatively narrow webbing-receiving slot  60 . Any desired combination of webbing widths can be obtained in similar fashion by interchanging modular components. 
     FIGS. 5-7A illustrate buckles including modular components having various functions. In FIG. 5, the buckle joins a first, webbing-receiving modular component  62  with a second modular component  64  that includes a hex ring  66 , e.g., for engagement with a snap hook. In FIGS. 6 and 6A, the buckle joins first and second modular components that each include webbing dividers, e.g., for joining webbing straps entering the clip from different directions. Webbing dividers  68  (FIG. 6) include three webbing-receiving openings  70  positioned to receive webbing straps at 0°, 90° and 180°, while webbing dividers  72  (FIG. 6A) include two webbing-receiving openings  74 , positioned to receive webbing straps at approximately 45° and 135°. In FIGS. 7 and 7A, the female buckle component  32  is joined to a modular component  78  that includes a snap hook  80 , and the male buckle component  34  is joined to a webbing-receiving modular component  62  as shown in FIG.  5 . In FIG. 7A, a first end  82  of a length of webbing  84  is threaded through the modular component  62 , and a second end  86  of the webbing  84  is threaded through slot  88  of hex ring  90 . The combinations shown in FIGS. 4-7A are merely a few examples of the many possible combinations of modular components. 
     The modular components may be assembled with the standardized buckle in other suitable ways. For example, enhanced strength is provided by the tongue-and-groove engagement that is shown in FIGS. 8-10A. An elongated bar  100  is provided on the modular component  31 , and a receiving slot  102  dimensioned to receive the bar  100  is provided on the standardized buckle  32 . (While female buckle component  32  is shown for purposes of illustration, the same tongue 20  and-groove engagement may be used with male buckle component  34 ). The elongated bar  100  is t-shaped in cross-section, i.e., it includes a base member  106  and a cross-bar  108  (see FIG.  8 D). The width of the cross-bar  108  tapers slightly along its length, from narrow end  110  to wide end  112 , so that one end is slightly wider than the other end, e.g., about 10-20% wider, more preferably about 15% wider. Receiving slot  102  includes a surface channel  103 , having a width sufficient to allow the base member  106  to slide freely along its length, and an interior channel  101  that is sufficiently wide to receive the cross-bar  108  in sliding engagement (see FIGS.  9 - 9 B). Thus, the width of channel  101  is slightly larger than the width of the wide end of cross-bar  108 . Receiving slot  102  also includes an end opening  105  that is narrower than the wide end of cross-bar  108 , e.g., by about 5-10%, more preferably about 7%. When crossbar  108  slides into receiving slot  102 , as shown in FIGS. 9-9A, end opening  105  must deflect slightly so that the wide end  112  (which is wider than opening  105 ) can pass through into interior channel  101 . Once wide end  112  has passed through end opening  105 , the walls of the end opening return to their normal position. In this position, the walls of end opening  105  overlap the wide end of the cross-bar, thus acting as a detent that prevents the cross-bar  108  from being withdrawn from interior channel  101 . Suitable dimensions for the cross-bar are, e.g., 4.1 mm at the narrow end  110 , increasing to 4.8 mm at the wide end  112 . A suitable width for the interior channel would be, e.g., approximately 5.0 mm, with the end opening  105  having an undeflected width of approximately 4.5 mm. When the tongue-and-groove engagement is used with a male buckle component, for molding purposes it may be desirable to alter the shape of the surface channel  103  to that shown in FIG. 8E so that the interior channel  101  can be formed more easily. 
     As shown in FIGS. 9-9B, the buckle and modular component are assembled by sliding the bar  100  into the receiving slot  102  until the buckle and modular component are aligned and wide end  112  is locked in place behind end opening  105 . The assembled buckle and modular component are shown in FIGS. 10 and 10A, with the dotted lines in FIG. 10A indicating the overlap of cross-bar  108  with the walls of end opening  105 . 
     If desired, the positions of the bar and receiving slot can be reversed, i.e., the buckle can include the bar  100  and the modular component can include the slot  102 . 
     Other embodiments are within the claims. 
     For example, while the invention has been discussed above in the context of side release buckles, the releasably engageable portions of a standardized buckle could be of any desired type, e.g., center release buckles or buckles having a half-twist locking mechanism. 
     Moreover, while in the preferred embodiments discussed above the buckle components include an open end and the modular components include prongs (i.e., the buckle components are “female” and the modular components are “male”), employing broad aspects of the invention, the reverse construction can be employed. In fact, employing broader aspects of the invention, any desired method of attachment can be used, provided that attachment can be performed relatively easily and that adequate strength and performance properties are provided. Likewise, when modular components are attached to the buckle components using an automated process, in the factory, the components may be joined in any suitable manner, such as various types of interference engagement, e.g., the parts may be press fit and subsequently ultrasonically welded. Other suitable methods of attachment include adhesive bonding and vibration welding, e.g., ultrasonic welding. 
     While the engagement of the modular component with the buckle component is permanent in the embodiments described above, employing broader aspects of the invention the standardized buckle and the modular components can be constructed to releasably engage. 
     Also, while both the male and female buckle component shown and described above are constructed to receive a modular component, in some embodiments only one of the buckle components will include this feature.