Abstract:
The coupling includes a main body with a fixed frame and a locking pawl. A carriage and impact member are connected in spring-biased fashion to the frame. The carriage controls locking of the pawl while the impact member continually urges the pawl in a counterclockwise direction. Pressing the release button causes the carriage to separate from the pawl permitting the impact member to rotate the pawl to permit entry and exit of a LATCH loop into locking communication with the tooth of the pawl. When the button is released, the carriage maintains the pawl open until a LATCH loop is impacted into the back of the pawl to disengage it from the carriage to lock the pawl closed. The invention includes a fail safe measure to maintain locking when any of the springs fail and the ability to accommodate loads much heavier than prior art couplings.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
       [0001]    This application is related to and claims priority from earlier filed provisional patent application Ser. No. 61/099,942 filed Sep. 25, 2008, the entire contents thereof is incorporated herein by reference. 
     
    
     BACKGROUND OF THE INVENTION 
       [0002]    The present invention relates generally to child restraint and safety devices. More specifically, the present invention relates to child restraint and safety (CRS) devices, such as child car seats and booster seats. 
         [0003]    In the prior art, child safety restraints, such as those for use in a vehicle are very well known in the art. Such restraints are secured to an existing vehicle car seat. The child is then secured to the restraint to secure the child during travel. These prior art restraints are typically in the form of a booster seat or a child car seat. A booster seat is commonly known as a seat that attached to an existing vehicle seat where the seat uses the existing belt restraint system of the vehicle. Such a booster seat is commonly used for older children. Also, a child restraint may be in the form of a child car seat which is secured itself directly to the vehicle, such as by the car&#39;s seat belt system or directly to the frame of the vehicle using hooks, and other attachment mechanisms and systems. 
         [0004]    Many countries around the world have standardized how a child car seat is to be secured to a vehicle seat to improve the overall safety of children&#39;s car seats in vehicles. More specifically, a system called Lower Anchors and Tethers for Children (LATCH) includes two lower anchor attachments and a top tether. The term is often used generically to refer only to the pair of fixed lower loop shaped anchors built into the bight or crack between the seat back and seat cushion.  FIG. 1  shows such a prior art anchor system  10  with a lower loop  12 , typically made of metal, which are specifically designed for children&#39;s car seat installation. The loop  12  typically emanates between the vehicle seat back  14  and the seat bottom  16 , collectively referred to as the vehicle seat  18 . A female seat buckle  15  can also be seen in  FIG. 1 , which is not used as part of a LATCH interconnection of a child seat (not shown in  FIG. 1 ). When used, existing seatbelts are no longer necessary to connected to a buckle  15  to install the car seat because the child car seat is mounted directly to the vehicle via the metal loops  12  using webbing or a “rigid” connector. For example, the loops  12  extend down and connect directly to the chassis of the vehicle. This construction is so well known in the art that it need not be discussed in further detail herein. Also, one loop  12  is shown in the figures but it should be understood that multiple loops are typically employed in a LATCH or other type of anchorage system. 
         [0005]    This makes it easier to install car seats safely, and to make it more universal among car seats and vehicles. Compatible corresponding LATCH coupling systems are now commonly found on child car seat bases, rear-facing, front-facing and combination booster seats and those that have an internal harness. 
         [0006]    The LATCH system was originally called ISOFIX, which is a term still used in Europe. Canada, employs a similar standard called the Universal Anchorage System (UAS). It has also been called the Universal Child Safety Seat System or UCSSS. All of foregoing systems refer to the same universal anchorages  12  that started to appear on car models starting in about the year 2000. These are now required by law in the United States for almost all model year 2003 and later vehicles. 
         [0007]    As seen in  FIG. 2 , a child car seat, generally referenced as  19 , is secured directly to the loop  12  of a LATCH system by use of webbing  20  included with the child car seat  19 . The webbing  20  is routed through the loop  12  of the LATCH system and then tensioned to tightly tether the child car seat  19  to the vehicle car seat  18 . One or more LATCH loops  12  can be used to respectively tether one or more points or locations of the child car seat  18  in place. Looped tensioned webbing  20  through a LATCH loop  12  is undesirable because it must be threaded through the LATCH loop  12 . As an alternative, rigid interconnects can be used, as will be discussed in detail below. 
         [0008]    More preferably, a coupling  40  is employed to releasably interconnect the free webbing attached to the child car seat to the LATCH loop(s)  12 . This facilitates and speeds up the installation of a child car seat  19  to the LATCH loops  12 .  FIGS. 3 and 4  illustrate a lower anchor coupling  40  that is known in the art for this purpose. As can be seen in  FIG. 3 , the coupling  40  includes a closed loop  42 , that defines a aperture  44 , such as a slot, to receive the webbing that is attached to the child car seat. Details of such webbing  20  and the tensioning thereof need not be discussed in further detail herein because they are so well known in the art. It should also be understood that the prior art coupling may use a rigid member (not shown) that is affixed directly to a vehicle seat  18  to avoid the use of webbing  20 . Similarly, as below, the present invention may also employ a rigid connection member (not shown) rather than a loop and aperture that receives webbing routed from and connected to the child car seat  19 . 
         [0009]    More specifically, the prior art coupling  40  includes an outer housing  46  with a button  48  that is interconnected to locking pawl  50  in the open side can be disengaged by actuation of the button  48 . The locking pawl  50  is spring-biased to a closed position. Preferably, the open side of the coupling  40 , with webbing  20  attached to the opposite side thereof, is pressed over the LATCH loop to temporarily open the pawl  50  so that the LATCH loop  12  is captured by the pawl  50 . To release the LATCH loop  12  from the locking pawl  50 , the button  48  is actuated so the coupling  40  can be disconnected to free the child car seat  19  from the LATCH system of the vehicle. 
         [0010]    While the prior art lower anchor coupling is useful in many respects, it suffers from many disadvantages. These couplings were only designed for use with lower weight children, for example, 48 lbs or less. There is a need for coupling that can accommodate higher weight children because there is a trend in car seat design to provide children&#39;s car seats for higher weight children. 
         [0011]    The primary problem associated with the prior art coupling  40  of  FIGS. 3 and 4  is that it is not designed for these increased loads. The actual internal operating mechanism itself is not robust enough to take the loads of a higher weight occupant in a child car seat  19 . Also, the design of this prior art coupling  40  suffers from an off-center webbing connector loop  42  which results in uneven/asymmetrical loads to the coupling  40 , which reduces the structural integrity of the coupling  40  and the entire child car seat installation. Also, the location and direction of travel of the release button  48  of this prior art coupling  40  is cumbersome and difficult to use. The locking pawl  50  of this prior art device is only a single piece of steel, resulting in a relatively small bearing and support area. This limits the overall strength and integrity of the coupling  40 . In summary, the prior art lower anchor coupling  40  of  FIGS. 3 and 4  is inadequate for securing child car seats  19  with large loads, such as child car seats with larger children seated therein. 
         [0012]    Still further, the prior art coupling  40 , as with other prior art couplings, suffers from the disadvantage of disconnecting if any of the springs fail within the device. For example, pawl  50  is spring-biased to a normally closed condition, as seen in  FIG. 4 . If the spring that retains pawl  50  in this condition fails, the pawl  50  would open thereby permitting the loop  12  of the LATCH system to separate from the child seat  19  creating a safety issue. 
         [0013]    Therefore, there is a need for an improved coupling for LATCH systems that can tether webbing, which is attached to a child car seat, to a loop of a LATCH system of a vehicle. There is a need for a coupling that has the strength and integrity to secure child car seats with larger loads therein, such as children that weigh over 48 pounds. There is a further needs for a LATCH coupling that is easy to use, namely, one that is easy to install and disconnect. There is yet a further safety problem that if any of the springs fail in a typical prior art coupling, the entire device will be unable to maintain a safe connection between the child seat  19  and the vehicle seat  18 . 
       SUMMARY OF THE INVENTION 
       [0014]    The present invention preserves the advantages of prior art child restraint devices, such as child seats and booster seats and couplings therefor. In addition, it provides new advantages not found in currently available devices and overcomes many disadvantages of such currently available devices. 
         [0015]    The invention is directed to a new and novel coupling that has particular use as an anchor for a child seat to secure it to a vehicle. The coupling includes a main body member having an open end capable receiving a lower anchor, attached to a vehicle, therein. A pawl is rotatably connected to the main body member where the pawl includes a tooth that defines an anchor seat region, a lower portion, a rear bearing surface, and a lock seat. The pawl is rotatable between a locked condition where the tooth spans across the open end of the main body member and prevents the lower anchor from being removed from the anchor seat region and an open condition where the lower anchor can freely move in an out of the anchor seat region and be separated from the main body member. 
         [0016]    A lower impact member is connected to the main body member and is in spring-biased communication with the lower portion of the pawl thereby urging the pawl to rotate in a first direction to remove the tooth from the open end. A carriage is connected to the main body and is spring-biased into communication with the rear bearing surface of the pawl thereby preventing the pawl from rotating in a second direction, opposite the first direction, to remove the tooth from the anchor seat region via the open end. 
         [0017]    A button is connected to the carriage, which is in communication with the lock seat of the pawl when the button is in a released state. The carriage is separated from the lock seat of the pawl when the button is depressed. The lower impact member communicates with the lower portion of the pawl to pivot the pawl into an open condition suitable for receipt of an anchor member into the anchor seat region of the pawl via the open end thereof when the button is depressed. The carriage communicates with the lock seat of the pawl when the button is not depressed. 
         [0018]    Also, the button, carriage and pawl are configured so that when after the button is depressed and then released, the carriage communicates with the rear bearing seat of the pawl to maintain it in an open condition until an anchor member is inserted into the open end of the body member and into communication with the pawl to disengage the carriage from the rear bearing seat. 
         [0019]    The coupling can accommodate loads that are larger than prior art couplings due to the configuration and size of the locking pawl. Also, the present invention includes a fail safe feature where the coupling will continue to stayed locked onto a LATCH loop even if one or both of the spring-biasing member fail within the device. 
         [0020]    It is therefore an object of the present invention to provide a coupling that can connect a child car seat to a vehicle anchor member, such as metal loop of a LATCH system in a vehicle. 
         [0021]    It is an object of the present invention to provide a coupling that is easy and safe to operate. 
         [0022]    A further object of the present invention is to provide a lower anchor coupling that is less likely to disconnect than prior art couplings. 
         [0023]    Another object of the present invention is to provide a lower anchor coupling that will remain locked even if the springs fail within the device. 
         [0024]    Yet a further object of the present invention is to provide a lower anchor coupling that can accommodate a load of up to 48 pounds or higher, such as 80 pounds. 
         [0025]    Another object of the invention is to provide a coupling with a fail safe feature so that the coupling will continue to lock a child seat to a vehicle&#39;s LATCH loop even if the spring-biasing in the device fails. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0026]    The novel features which are characteristic of the present invention are set forth in the appended claims. However, the invention&#39;s preferred embodiments, together with further objects and attendant advantages, will be best understood by reference to the following detailed description taken in connection with the accompanying drawings in which: 
           [0027]      FIG. 1  is a loop of a prior art anchor system for a vehicle for connection of a child seat thereto; 
           [0028]      FIG. 2  shows a prior art interconnection of a child seat to the loop of  FIG. 1  using webbing material; 
           [0029]      FIG. 3  is a rear perspective view of a prior art lower anchor coupling; 
           [0030]      FIG. 4  is a front perspective view of a prior art lower anchor coupling; 
           [0031]      FIG. 5  is a front perspective view of a lower anchor coupling in accordance with the present invention in a locked condition; 
           [0032]      FIG. 6  is a top view of the lower anchor coupling of  FIG. 5 ; 
           [0033]      FIG. 7  is a cross-sectional view through the line  7 - 7  of  FIG. 6 ; 
           [0034]      FIG. 8  is a front perspective view of the lower anchor coupling of the present invention in an open condition; 
           [0035]      FIG. 9  is a top view of the lower anchor coupling of  FIG. 8 ; and 
           [0036]      FIG. 10  is a cross-sectional view through the line  10 - 10  of  FIG. 9 . 
       
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
       [0037]    The present invention provides a new and novel coupling  100  for interconnecting a child car seat  19 , as seen in  FIG. 2 , to a loop  12  of a vehicle&#39;s LATCH system, as seen in  FIGS. 1 and 2 , through a vehicle seat  18 .  FIGS. 5-7  show the coupling  100  of the present invention in a closed condition while  FIGS. 8-10  show the coupling  100  in an open condition. 
         [0038]    Turning First to  FIGS. 5-7 ,  FIG. 5  shows a perspective view of the coupling  100  in the closed condition. This lower anchor coupling  100  is used to secure the child restraint (CRS) to the vehicle via two 6 mm diameter bars/loops  12 , as in  FIGS. 1 and 2 , which are required by federal law to be located in the bite of the vehicle seat  18 . Typically, the coupling  100  is used in pairs to respectively couple two portions of the seat  19  to the two bars/loops  12  of the LATCH system. The present invention easily attaches to a given bar/loop  12  of the LATCH system in a vehicle seat  18 . 
         [0039]    Since webbing  20  and tightening components are so well known in art, they need not be discussed in detail herein. Also, coupling  100  of the present invention may also employ a rigid connection member (not shown) rather than webbing routed from the child car seat  19  to the loop  12 . Or, for example, the coupling  100  may be integrated directly into a child car seat  19 . Thus, the coupling  100  of the present invention may be easily modified to accommodate this interconnection method and still be within the scope of the present invention. 
         [0040]    Turning now to details of the construction of the coupling  100  of the present invention. The coupling includes a main body  102  with a loop of material  104  with a slot  106 , such as one that is D-shaped, at one end to receive the appropriate webbing that is attached to the seat. The loop of material  104  may be an extension of or integrated into a backing plate  109  that resides in the main body  102 . 
         [0041]    As can be seen in  FIG. 6 , the loop of material  104  with slot  106  is located on the longitudinal centerline of the main body  102  to provide a well balanced connection. The opposing end of the main body includes a opening  108  that includes a locking pawl, generally referred to as  110 , which is preferably multiple pawl members stacked side by side, as seen in  FIG. 5 , or one wide pawl member  110  to increase strength and integrity of the locking and to accommodate heavier loads, such as children over 48 pounds. Such a strong pawl  110  enables the coupling  100  of the present invention to accommodate loads up to 80 pounds or more.  FIG. 6  shows a top view of the coupling to illustrate that the loop of material  104  and slot  106 , such a one that is D-shaped, is symmetrically oriented transversely across the width of the coupling  100 . Also, the button  112  is accessed on the top of coupling  100  through an aperture  114  in the main body  102 . As a result, the coupling  100  is easier to use and more well balanced than prior art devices. 
         [0042]      FIG. 7  shows a cross-section of the coupling  100  in a locked condition. A locking pawl  110  pivots about a pivot point. Multiple pawl plates can be secured together to provide one large and thick pawl member  110 . A sliding carriage  116  is spring-biased to the right to sit underneath a back seat notch  110   b  of the pawl  110 . A frame  120  is fixed to the main body  102  preferably via the backing plate  109 . One or more springs  122  (one seen in  FIG. 7 ) spring-biases of the sliding carriage  116  to the right due to the engagement of the spring  122  on post  124  on the carriage  116  and post  126  on the frame  120 . Other constructions may be employed for spring-biasing the carriage  116 . 
         [0043]    Pawl  100  is rotatably connected to the main body  102  via pin or axle  117 . The spring-biased carriage  116  to the right prevents the pawl  110  from rotating counterclockwise about pivot pin  117  to permit the LATCH loop  12  to release from the tooth  110   a  of the pawl  110  thereby permitting the child car seat  19  to separate from the LATCH system  12 . 
         [0044]    A lower impact member  126  is also provided which is independently spring-biased to the right toward the lower portion  110   c  of the pawl  110 . One or more springs  128 , preferably two, are used for the spring-biasing of the lower impact member  126 . A fixed pin  130  slidably resides in slot  132  of release button  112  for alignment thereof. The free lower end of the button  112  includes a pin  134  that slidably resides in slot  136  in the rear portion of the sliding carriage  116 . The locking condition, shown in  FIG. 7 , the locking pawl  110  is prevented from rotating in a counterclockwise direction thereby securely capturing the LATCH loop  12  behind the tooth  110   a  of the pawl  110 . 
         [0045]    To separate a child car seat  19  from a LATCH system loop  12  in a vehicle seat  18 , the coupling  100  must be opened to release the LATCH loop  12  from the embrace of the locking pawl  110 .  FIG. 8  shows a perspective view of the coupling  100  of the present invention in this open condition. As can be seen, the release button  112  is not clearly seen in  FIG. 8 . because it has been depressed to actuate the locking pawl  110  open, as will be described in detail below. The release button  112  can, however, still be clearly seen in top view  FIG. 9  and in the cross-sectional view of  FIG. 10 . 
         [0046]      FIG. 10  shows a cross-sectional view of the coupling  100  in an open condition. The release button  112  is depressed to urge the sliding carriage  116  rearwardly because the pin  134  of the button  112  slides in the angled slot  136  of the sliding carriage  116 . As a result, the sliding carriage  116  is no longer residing underneath the back seat portion  110   b  of the locking pawl  110  permitting it to freely rotate, namely, in the counterclockwise direction. The spring-biased lower impact member  126  continues to push to the right into the lower portion  110   c  of the pawl  110  to urge the pawl  110  to rotate in a counterclockwise direction about axle  117 . However, since the sliding carriage  116  is no longer residing underneath the notch  110   b  of the pawl  110 , the impact member  126  will impact the lower portion  110   c  of the pawl to cause it to rotate in a counterclockwise direction. As a result, the tooth  110   a  of the pawl  110  moves upwardly thereby permitting the loop  12  of the LATCH system to be easily removed from the opening  108  in the main body  102  of the coupling  100 . Since the impact member  126  is positioned below the centerline of the locking pawl  110 , a relatively small amount of force is required to keep the pawl  110  disengaged. 
         [0047]    When the release button  112  is disengaged, the locking pawl  110  will stay open because the impact member  126  will continue to push on the lower portion  110   c  of the pawl  110  and the sliding carriage  116  will bear against the rear surface  110   d  of the locking pawl  110 . When the coupling of the present invention is desired to be installed, the opening  108  of the coupling  100  is routed over a LATCH loop  12  which will impact the back wall  110   e  of the pawl  100  thereby causing the pawl  100  to rotate clockwise and against the forces of the spring-biased impact member  126 . As a result, the rear surface  110   d  of the pawl  110  disengages with the sliding carriage  116 . Further clockwise rotation of the pawl  110  enables the sliding carriage  116  to be urged to the right and back underneath notch  110   b  at the rear of the pawl  110 . The release button  112  will then return to its upward position and the pawl  110  will be again in a locked condition, as per above. 
         [0048]    Also, if the locking pawl  110  is closed and the installation on a LATCH loop is desired, the button can be depressed to open up the pawl  110 . Or, with the locking pawl  110  still closed, the coupling  100  can be directly pressed on loop  12  of the LATCH system so that the loop  12  engages with the arcuate leading edge  110   f  of the pawl  110  to urge the pawl  110  upwardly. When the loop  12  clears past the tooth  110   a  of the pawl  110 , the pawl  100  will remain open. As per above, further urging of the loop  12  into the coupling and into engagement of the notch  110   e  of the pawl  110  causes the desired counterclockwise movement of the pawl  110  and resultant locking. 
         [0049]    The foregoing coupling configuration of the present invention provides a fail safe interconnection that is not possible in the prior art. If any of the springs  122 ,  128  fail, the pawl  110  will remain locked. For example, if spring  122  fails, the spring-biasing of the impact member  126  by spring  128  would continue to urge the pawl  110  counter clockwise which results in continued downward pressure onto the carriage  116 . On the other hand, if the lower spring  128  fails, the spring-biasing of the carriage  116  by upper spring  122  would still prevent counterclockwise rotation of pawl  110 , thereby preventing the pawl  110  from opening. As a result, the carriage  116  would remain underneath the pawl  110  thereby maintaining a locked condition. 
         [0050]    It should be noted that the coupling  100  of the present invention can be made of any suitable materials. For example, the entire device  100  may be made from metal, such as steel. The main body  102  may be made of plastic, for example, or other material. 
         [0051]    In view of the foregoing, a new and novel coupling  100  is provided for use in child car seats  19  and vehicle seat  18  that use a LATCH or similar standardized anchor system that uses a fixed loop  12  of material The coupling  100  of the present invention is stronger, easier to use, has more integrity and can accommodate larger loads than prior art couplings. 
         [0052]    It would be appreciated by those skilled in the art that various changes and modifications can be made to the illustrated embodiments without departing from the spirit of the present invention.