Patent Publication Number: US-9415247-B2

Title: Quick release connector for fall protection

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application claims the priority benefit of U.S. Provisional Patent Application Ser. No. 61/775,612, filed Mar. 10, 2013, which is incorporated herein by reference in its entirety. 
    
    
     BACKGROUND 
     1. Field 
     The embodiments relate to fall protection devices, and in particular to quick release connectors. 
     2. Description of the Related Art 
     Workers that work in elevated environments may employ fall protection gear, such as a fall protection harness and lanyard with a buckle. The current buckles include manually released pawls (e.g., locking portions) that are susceptible to accidental release based on a workers movement and contact with the pawls with elements in the work environment (e.g., bumping into objects, leaning on objects, handling of other gear, etc.). 
     SUMMARY 
     One embodiment provides a quick release buckle includes a main body portion including a top housing portion and a bottom housing portion. A t-bar element removably connects within the main body portion. A pair of locking pawls removably connect with an extension portion of the t-bar element. A locking wheel device is configured for locking and unlocking the pair of pawls based on contact of pawl extensions with one or more portions of the locking wheel device. 
     Another embodiment provides a system including a fall protection safety harness. A quick release buckle is coupled with the fall protection safety harness. In one embodiment, the quick release buckle comprises: a main body portion including a top housing portion and a bottom housing portion; an insertion element that removably couples within the main body portion; a pair of pawls that removably couple with an extension portion of the insertion element; and a rotating device that is configured for locking and unlocking the pawls based on contact of a portion of the pawls with one or more portions of the rotating device. 
     One embodiment provides a quick release buckle comprising a main body portion. A buckle insertion element removably couples within the main body portion. In one embodiment, two or more locking pawls removably couple with an extension portion of the buckle insertion element. In one embodiment, a rotating device is configured for preventing the two or more pawls from movement internal to the main body portion based on contact of pawl extensions with one or more portions of the rotating device. 
     Other aspects and advantages of the present invention will become apparent from the following detailed description, which, when taken in conjunction with the drawings, illustrate by way of example the principles of the invention. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The embodiments are illustrated by way of example, and not by way of limitation, in the Figures of the accompanying drawings and in which like reference numerals refer to similar elements and in which: 
         FIG. 1  illustrates a perspective view of a quick connect buckle with locking pawls, according to one embodiment; 
         FIG. 2  illustrates a top view of a quick connect buckle with locking pawls, according to one embodiment; 
         FIG. 3  illustrates a bottom view of a quick connect buckle with locking pawls, according to one embodiment; 
         FIG. 4  illustrates an exploded view of a quick connect buckle with locking pawls, according to one embodiment; 
         FIG. 5  illustrates an isolated view of a male T-bar for a quick connect buckle with locking pawls, according to one embodiment; 
         FIG. 6  illustrates an isolated view of a knob wheel for a quick connect buckle with locking pawls, according to one embodiment; 
         FIG. 7  an isolated view of lock/release knob for a quick connect buckle with locking pawls, according to one embodiment; 
         FIG. 8  illustrates an isolated view of locking pawl for a quick connect buckle, according to one embodiment; 
         FIG. 9  illustrates a bottom internal view of a quick connect buckle with locking pawls, according to one embodiment; and 
         FIG. 10  illustrates a top internal view of a quick connect buckle with locking pawls, according to one embodiment. 
     
    
    
     DETAILED DESCRIPTION 
     The following description is made for the purpose of illustrating the general principles of the invention and is not meant to limit the inventive concepts claimed herein. Further, particular features described herein can be used in combination with other described features in each of the various possible combinations and permutations. Unless otherwise specifically defined herein, all terms are to be given their broadest possible interpretation including meanings implied from the specification as well as meanings understood by those skilled in the art and/or as defined in dictionaries, treatises, etc. 
     The description may disclose several preferred embodiments of fall protection quick release buckles (e.g., for safety harnesses) with locking pawls systems and devices, as well as operation and/or component parts thereof. While the following description will be described in terms of fall protection quick release buckles with locking pawls systems and devices for clarity and to place the invention in context, it should be kept in mind that the teachings herein may have broad application to all types of systems, devices and applications. 
     One embodiment of the invention provides a quick release buckle includes a main body portion including a top housing portion and a bottom housing portion. In one embodiment, a t-bar element removably connects within the main body portion. In one embodiment, a pair of locking pawls removably connect with an extension portion of the t-bar element. A locking wheel device is configured for locking and unlocking the pair of pawls based on contact of pawl extensions with one or more portions of the locking wheel device. 
       FIG. 1  illustrates a perspective view of a quick connect buckle  100  with locking pawls  150 / 151 , according to one embodiment. In one embodiment, the quick connect buckle  100  includes a top housing portion  110 , a bottom housing portion  111 , T-bar or insertion element (e.g., buckle insert)  120  with a belt/webbing opening  125 , lock/release knob  130 , belt/webbing adjusting/locking roller  140 , and locking pawls  150  and  151  ( FIG. 2 ). In one embodiment, the quick connect buckle  100  may be implemented with a safety harness (e.g., a web/webbing harness, safety vest, safety suit, etc.) for fall protection. In other embodiments, the quick release buckle  100  may be implemented in other safety uses, such as safety belts connected to safety lines, or any other product that may require additional safety features of locking pawls for a quick release buckle system. In one embodiment, the quick connect buckle  100  provides a heightened level of security with a pawl locking feature implemented by turning the lock/release knob  130 . 
     In one embodiment, the top housing portion  110  may be made out of high strength, lightweight aluminum material. In other embodiments, the top housing portion may be made out of other strong materials, such as metals, metal alloys, etc. In one embodiment, the top housing portion  110  may comprise a molded component designed to house or encapsulate the lock/release knob  130 , the knob wheel or rotating element  420  ( FIG. 4 ) and the locking/release pawls  150  and  151  ( FIG. 2 ). 
     In one embodiment, the male T-bar  120  may be made in high strength steel, metal alloy materials, or other similar strength material. In one embodiment, the T-bar  120  is may be inserted into the female opening  126  formed between the top housing portion  110  and the bottom housing portion  111  to automatically lock with the pawls  150  and  151  until a user manually releases the pawls  150  and  151  using the lock/release knob  130  allowing the male T-bar  120  to be removed from the female opening  126  for the quick release buckle  100  to be disengaged. 
     In one embodiment, the pawls  150  and  151  ( FIG. 2 ) may be made of brass, steel, aluminum or similar strength materials. In one embodiment, the pawls  150  and  151  are attached firmly between the top housing portion  110  and the bottom housing portion  111  allowing a portion of the pawls  150  and  151  to protrude out of the housings to act as manual release levers when the lock/release knob  130  is not in a locking position. In one embodiment, the internal portion of the pawls  150  and  151  serve as spring  910  ( FIG. 9 ) operated, and an auto locking mechanism on the quick connect buckle  100 . 
     In one embodiment, the lock/release knob  130  engages the knob wheel  420  ( FIG. 4 ) that is housed between the top housing portion  110  and the bottom housing portion  111 . In one embodiment, the knob wheel  420  may be made out of a high strength composite material. In one embodiment, the knob wheel  420  is attached to the lock/release knob  130  that is accessible from the outer surface of the top housing portion  130  and serves as the pawl  150  and  151  locking mechanism that prevents the pawls  150  and  151  from being manually depressed toward the housing formed from the top housing portion  110  and the bottom housing portion  111 . In one embodiment, the lock/release knob  130  may be made of a high strength composite material. In one embodiment, the lock/release knob  130  allows a user to lock or unlock the pawls with a simple 180 degree turn (either clockwise or counter-clockwise) In one embodiment, turning the lock/release knob  130  may unlock the pawls  150  and  151  allowing users to manually depress the pawls  150  and  151  for releasing the T-bar  120 . In one embodiment, turning the lock/release knob  130  back 180 degrees provides for locking the pawls  150  and  151  by preventing the inner portion of the pawls  150  and  151  from moving inwards and preventing the T-bar  120  from being released (intentionally or unintentionally). In one embodiment, as a further safety advantage the lock/release knob  130  has a window or opening  710  ( FIG. 7 ) allowing the indicator  438  ( FIG. 4 ) to be viewed (e.g., a red indication for indicating an unlocked state and a green indication for indicating a locked state, markings, etc.). 
     In one embodiment, the body of the quick release buckle  100  may be made of a molded and tooled top housing portion  110  made of aluminum, while the bottom housing portion  111  may be made of a solid layer of steel riveted to the top housing portion  110 . In one embodiment, as assembled, the female formed housing (between the top housing portion  110  and the bottom housing portion  111 ) is designed to connect with harness webbing and the male T-bar  120  end. Inside the female formed housing the pawls  150  and  151  ( FIG. 2 ) are positioned and fixed with fasteners, such as rivets, so they protrude out of the female housing and inside the female housing. In one embodiment, the pawl portion inside the housing connects with the male T-bar extension portion  430  ( FIG. 4 ) allowing the quick connect buckle  100  to be “connected.” 
       FIG. 2  illustrates a top view of the quick connect buckle  100  with locking pawls  150  and  151 , according to one embodiment. In one example embodiment, as shown the T-bar  120  is inserted into the female formed housing between the top housing portion  110  and the bottom housing portion  111 .  FIG. 3  illustrates a bottom view of a quick connect buckle  100  with locking pawls  150  and  151 , according to one embodiment. 
       FIG. 4  illustrates an exploded view of a quick connect buckle  100  with locking pawls  150  and  151 , according to one embodiment. In one embodiment, the quick connect buckle  100  includes fasteners (e.g., rivets)  160  and  161  that attach the top housing portion  110  with the bottom housing portion through the openings  460  and  461 , respectively. In one embodiment, a fastener  162  may be placed though the opening  452  and through openings in the top housing portion  110  and bottom housing portion  111  for rotational movement of the pawl  150  (and similar components/opening for pawl  151  and its opening  453 ). 
     In one embodiment, fasteners  428  and  429  attach the knob wheel  420  to the lock/release knob  130  through holes  601  and  602  ( FIG. 6 ) in the fitment portion  427 . In one embodiment, the belt/webbing adjusting/locking roller  140  includes ends  410  that allow the belt/webbing adjusting/locking roller  149  to slide or lock within the space  145  between the top housing portion  110  and the bottom housing portion  111 . 
     In one embodiment, the indicator  438  includes a red portion and a green portion (and or indicator words or markings, such as locked, safe, etc., and unlocked, open, unsafe, etc.) on its top portion that are visible through the window  710  ( FIG. 7 ) in the lock/release knob  130 . In one embodiment, the indicator  438  may be placed on the knob holder  439 . In one embodiment, the indicator  438  may be a sticker or other material that is permanently fixed to the knob holder  439 . In other embodiments, the indicator  438  is not used, but instead permanent indicators are painted or adhered to the knob holder  439 . 
     In one embodiment, the opening  425  and slot/groove  426  make up a “snap to lock” system, which allows the user to feel and hear when the lock/release knob  130  has been placed in the fully locked position or into the fully unlocked position. In one embodiment, the nub or protrusion  426  is placed on sculpted out swing arm of off the main pawls  150  and  151  locking structure. In one embodiment, the arm  425  allows the nub  426  to swing slightly ensuring it finds its preset indicator cavities built into the top housing portion  110 . In one embodiment, when the nub  426  reaches the cavities in the top housing portion  110 , the nub  426  snaps into the cavity indicating to the user they have turned the lock/release knob  130  to its desired end location, either locked or unlocked. 
     In one embodiment, the pawl extensions  451  and  452  operates as flanges or locking locations for portions of the knob wheel  420 , which are secondary locking wheel mechanisms (i.e., in addition to the locking action of the T-bar extension portion  430  on the pawls  150  and  151 ). In one example embodiment, when the lock/release knob  130  is turned, the knob wheel  420  turns to prevent the pawls and pawl extensions  151 / 451  and  150 / 450  from moving. In one embodiment, the knob wheel  420  is shaped such that when the knob wheel  420  is turned from the locked position by 180 degrees, the pawls  150  and  151  may be freely moved to disengage the T-bar  120  from the female opening  126 . 
       FIG. 5  illustrates an isolated view of a male T-bar  120  for a quick connect buckle  100  with locking pawls  150  and  151 , according to one embodiment. In one embodiment, the extensions  430  push past the pawls  150  and  152  that have tension due to springs  910  ( FIG. 9 ) pressing on them, and lock in place against the pawl ends  911  ( FIG. 9 ) (unless the pawls  150  and  151  are pressed manually inward when the lock/release knob  130  is in the un-locked position/state.  FIG. 6  illustrates an isolated view of the knob wheel  420  for a quick connect buckle  100  with locking pawls  150  and  151 , according to one embodiment. 
       FIG. 7  an isolated view of lock/release knob  130  for a quick connect buckle  100  with locking pawls  150  and  151 , according to one embodiment. In one embodiment, the window  710  provides for view indicators, such as indicators on the indicator  438  (e.g., red/green indicators indicating locked/unlocked). 
       FIG. 8  illustrates an isolated view of locking pawl  150  for a quick connect buckle  100 , according to one embodiment. In one embodiment, the pawl extension  450  provides for locking the pawl  150  against the knob wheel  420  when the lock/release knob  130  is in the locked position/state. 
       FIG. 9  illustrates a bottom internal view of a quick connect buckle  100  with locking pawls  150  and  151 , according to one embodiment. In one example embodiment, springs  910  are engaged in placement holders or slots and compress/expand to maintain a force on the pawl ends  911 . In one embodiment, the T-bar  120  is inserted into the female opening  126  and contact the pawl ends  9111  and force the pawls  150  and  151  to rotate and force the springs to compress, which allows the T-bar extensions  420  to force past the pawl ends  911  until the pawls  150  and  151  rotate back based on the spring action from the springs  910 . The T-bar ends  430  are then prohibited from being removed from the contact with the pawl ends  911  unless the pawls  150  and  151  are pressed inwards to rotate the pawl ends outwards away from the T-bar extensions  430 . 
       FIG. 10  illustrates a top internal view of a quick connect buckle  100  with locking pawls  150  and  151 , according to one embodiment. In one example embodiment, the knob wheel  420  is shown in a locked state/position where the pawl extensions  450  and  451  are locked by the portion of the knob wheel  420  preventing the pawls  150  and  151  from being depressed (either intentionally or unintentionally). In one embodiment, the pawl extensions  451  and  450  contact the knob wheel  420  in the locked state/position and prevent the pawls  150  and  152  from being pressed inwards from outside of the quick release buckle  100 . It should be noted that in the unlocked state or position of the knob wheel  420 , the pawls  150  and  151  may be pressed inwards and the pawls ends  911  are allowed to move towards the knob wheel  420  based on the shape of the wheel, which allows the pawl extensions to move inward when the pawls  150  and  151  are pressed in. 
     In the description above, numerous specific details are set forth. However, it is understood that embodiments of the invention may be practiced without these specific details. For example, well-known equivalent components and elements may be substituted in place of those described herein, and similarly, well-known equivalent techniques may be substituted in place of the particular techniques disclosed. In other instances, well-known structures and techniques have not been shown in detail to avoid obscuring the understanding of this description. 
     Reference in the specification to “an embodiment,” “one embodiment,” “some embodiments,” or “other embodiments” means that a particular feature, structure, or characteristic described in connection with the embodiments is included in at least some embodiments, but not necessarily all embodiments. The various appearances of “an embodiment,” “one embodiment,” or “some embodiments” are not necessarily all referring to the same embodiments. If the specification states a component, feature, structure, or characteristic “may”, “might”, or “could” be included, that particular component, feature, structure, or characteristic is not required to be included. If the specification or claim refers to “a” or “an” element, that does not mean there is only one of the element. If the specification or claims refer to “an additional” element, that does not preclude there being more than one of the additional element. 
     While certain exemplary embodiments have been described and shown in the accompanying drawings, it is to be understood that such embodiments are merely illustrative of and not restrictive on the broad invention, and that this invention not be limited to the specific constructions and arrangements shown and described, since various other modifications may occur to those ordinarily skilled in the art.