Patent Abstract:
The present invention relates to an improved carabiner system, including an impact-dampening cushion around the external surface of the frame for cushioning damage during a fall or collision and to reduce sound from loose or swinging carabiner collisions. Additional surface routing and through holes provide improved register between the carabiner frame and the over-molded cushion layer.

Full Description:
INCORPORATION BY REFERENCE TO RELATED APPLICATIONS 
       [0001]    This patent application claims the benefit of priority to and is a continuation of U.S. Provisional Application No. 62/311,980, titled “Cushioned Carabiner Clip” and filed May 5, 2016, which is incorporated herein by reference in its entirety. 
     
    
     BACKGROUND 
     Field of the Invention 
       [0002]    This patent document relates to a fastening clip and methods of manufacturing and use thereof. This patent document relates more particularly to a carabiner clip including a cushion layer to reduce impact and damage from impact. 
       Description of the Related Art 
       [0003]    A carabiner is a mechanical device used to link rope, slings, or climbing aids together. Carabiners are popular in rope-intensive activities such as climbing, boating, sailing, farming/ranching, skydiving and aerial sports, construction, trucking, and safety systems. Carabiners are also used in less demanding roles as key rings, connecting water bottles to backpacks, holding electrical cords, securing animal leashes or restraints, or to quickly construct tents, canopies, or clotheslines. 
         [0004]    Carabiners typically consist of a rigid loop with a spring-loaded gate used to quickly and removably attach two components or a single component to a rope. Most carabiners include a frame, a gate, a hinge, and a spring. A traditional carabiner is generally a C-shaped frame connected to a spring-loaded, hinged gate. When the gate is closed, the C-shaped frame and gate form a closed loop around an interior cavity. When the gate is open, the opening between the gate and the C-shaped frame allows insertion of a rope or loop into the interior cavity. A spring provides force to return the gate to the closed position to prevent unintended detachment. 
         [0005]    Carabiners intended to secure heavy items, valuable property, or human bodies are constructed from stronger materials and thicker components if intended for carabiners. Lighter materials and thinner carabiners may be used for less intensive activities unrelated to safety. Stronger materials and thicker frames result in heavier and larger carabiners. 
         [0006]    The inventors here have found that the carabiners intended for use in certain activities can be unwieldy and cause injury and/or damage when released under tension or dropped. As an example, a heavy, steel carabiner used in recreational boating to connect moorings or tow ropes can easily crack or chip the fiberglass hull of an expensive boat if dropped or released. Additionally many climbers or construction workers have experienced unpleasant bumps and bruises from loose carabiner collisions. Accordingly, it is here recognized that a continued need exists to overcome and improve upon such shortcomings in conventional carabiners. In order to address the above-described exemplary problems, and other similar problems, what is needed is a cushioned carabiner that will absorb some of the shock of impact and dampen the noise produced by a loose carabiner without sacrificing durability or functionality, thereby providing enhanced functionality, safety, and convenience to the user. 
       SUMMARY 
       [0007]    Various aspects are described in connection with an illustrative implementation of the cushioned carabiner disclosed herein. The various aspects are disclosed in the written specification including the drawings, and claims, and may be combined to form claims for a device, apparatus, system method of manufacture and/or use in any way, consistent with the teachings herein, without limitation. 
         [0008]    The cushioned carabiner comprises a uniquely configured and constructed carabiner including a cushion layer attached to the spine of the carabiner frame. In some aspects, the cushion layer covers most or all exposed (internal and external) surfaces of the frame, excluding those areas that interfere with gate or mechanical movement. In some aspects, the cushion layer is molded to the frame and covers the external surface of the frame, cushioning the external areas likely to impact in a collision if dropped or swung. In some aspects the cushion layer covers only specific external surfaces of the frame, while in other aspects, the cushion may cover most or all of the outward facing surfaces of the frame. In some aspects, the internal surface of the carabiner frame may remain uncovered by the cushion layer so that the internal surface of the carabiner remains durable and low-friction for sliding ropes. In other aspects, some or all of the internal surfaces (facing toward the interior cavity) of the carabiner frame may include a cushion layer while the external surfaces remain exposed (or cushionless). In some aspects, the gate may also include a cushion layer on the external surface, on the interior surface, or on all surfaces. 
         [0009]    In some aspects, the cushion layer is thick and soft enough to significantly reduce the energy of impact. In other aspects, the cushion layer is intended to only dampen sound from clanging metal or to provide some level of external friction, so the cushion layer may be relatively thin or composed of alternate materials. In some aspects, the cushion layer is manufactured from silicon, rubber, synthetic rubber, plastic, plastic alternatives, fabric, plant matter, paper, recycled materials, cellulose, bioisoprene, resin, or any other cushioning material. In some aspects the frame and/or gate may be formed of the same or different materials, including (but not limited to) any of steel, stainless steel, 316 stainless steel, iron, aluminum, titanium, tin, zinc, copper, brass, bronze, wood, plastic, carbon fiber, and composite. In some aspects, the frame and/or gate are electro-polished or electro-coated. In some aspects, the frame and/or gate may include contours, grips, or additional curves. In some aspects, the frame and/or gate are forged, molded, carved, rolled, or pressed. In some aspects the frame is co-molded with the cushion layer. 
         [0010]    In various aspects, the carabiner can be formed in a variety of alternate shapes to optimize performance for specific purposes. In some aspects, the carabiner includes a locking mechanism, a wire gate or hollow gate, multiple gates providing access to multiple interior cavities, or multiple internal cavities accessed through a single gate. In another aspect, the carabiner frame may include an additional closed loop without a gate for securing ropes that are tied to the loop rather than clipped with a gate. In another aspect, the carabiner may include two or more separately-gated internal cavities. In further aspects, a carabiner may include multiple separately gated interior cavities connected by a rigid connecting structure. In still other aspects, a carabiner system may include multiple separate carabiners connected by a flexible rope, strap, or fastener. In another aspect, the hinge may be pivoted and the gate may instead open outward or to the side. In another aspect, various lock mechanisms may be provided to secure the gate and avoid inadvertent release. 
         [0011]    Various alternative implementations of the foregoing aspects are disclosed. The foregoing various aspects may be combined in any manner without limitation. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0012]      FIG. 1  is a right side view of an exemplary cushioned carabiner in the closed position, the cushioned carabiner comprising a cushion layer disposed on the external surface of the frame. 
           [0013]      FIG. 2  is a right side view of an exemplary cushioned carabiner in the open position, the cushioned carabiner comprising a cushion layer disposed on the external surface of the frame. 
           [0014]      FIGS. 3 and 4  are right and left side photographs of an exemplary cushioned carabiner frame before the cushion layer is connected, revealing the underlying structure. The depicted carabiner frame is shown without the gate and hinge. 
           [0015]      FIGS. 5 and 6  are right and left side photographs of an exemplary cushioned carabiner frame. The depicted carabiner frame is shown without the gate and hinge 
           [0016]      FIGS. 7 and 8  are right and left side photographs of an exemplary locking cushioned carabiners before the cushion layer is connected, revealing the underlying structure. The depicted carabiners include a screw-type locking mechanism and the gate is in the closed position. 
           [0017]      FIG. 9  is a left side view of an exemplary locking cushioned carabiner. The depicted carabiner includes a screw-type locking mechanism and the gate is in the open position. 
           [0018]      FIGS. 10 and 11  are alternate perspective views of a cushioned carabiner frame. 
           [0019]      FIG. 12  is a view of an alternate double-crotch cushioned carabiner frame. 
       
    
    
     DETAILED DESCRIPTION OF THE EMBODIMENTS 
       [0020]    The features, aspects and advantages are described below with reference to the drawings, which are intended to illustrate but not to limit the invention. In the drawings, like reference characters denote corresponding features consistently throughout the drawings.  FIGS. 1-11  illustrate various aspects of an embodiment of the cushioned carabiner  100 . It should be understood, however, that the teachings herein are not limited to any particular carabiner and are applicable to other fasteners. 
         [0021]    As illustrated in  FIGS. 1-11 , the carabiner frame  110  is a generally C-shaped metal piece with a gate opening  113  between the two ends  111 ,  112  of the frame  110 . The proximal end  121  of a gate  120  sized and dimensioned to span the gate opening  113  is affixed to a proximal end  111  of the frame  110  by a hinge  130  (comprising a hinge pin or rivet  132  inserted through both gate hinge hole  124  and frame hinge hole  133 ), and the distal end  122  of the gate  120  rests against or is otherwise in relative proximity to the nose or distal end  112  of the frame  110 . Together the frame  110  and gate  120  form a closed loop around an interior cavity  101 . The frame  110  and gate  120  each include external surfaces  102  and internal surfaces  103 . 
         [0022]    An inward force applied to the gate  120  can pivot the gate  120  around the hinge  130 , creating a gap between the distal end  122  of the gate  120  and the nose  112  of the frame  110 . While the gate  120  is open, ropes or loops can be fed through the gate opening  113 , and when the inward force is removed, a hinge spring  131  (not shown) applies pressure to return the gate  120  to its rest position and close the carabiner  100 , securing any loops or ropes in the interior cavity  101 . At rest, the hinge spring  131  applies pressure to the gate  120 , pressing it outward from the interior cavity  101  so that the distal end  122  of the gate  120  is pressed against or rests against a notch  117  in the nose  112  of the frame  110 , keeping the gate  120  from swinging open in response to any outward force applied from the interior cavity  101  (such as by a clipped rope). A lock  140  can be built into the gate, the frame, or the hinge that maintains the gate in a closed position. 
         [0023]    The cushion layer  150  can be attached directly to the surface of the frame  110  with adhesive (not shown), but surface texturing  118  (e.g., grooves, holes, or other surface adjustments that increase contact area and corners between the cushion layer  150  and the frame  110  or gate  120 ) significantly improves the connection and prevents peeling and damage. Through holes  119  allow the cushion layer  150  to flow through the frame  110 , significantly improving durability and attachment of the cushion layer  150 . 
         [0024]    With reference to  FIGS. 1 and 2 , carabiner frame  110  and/or gate  120  may be formed from a variety of metals, alloys, and rigid materials including, but not limited to steel, stainless steel, 316 stainless steel, iron, aluminum, titanium, tin, zinc, copper, brass, bronze, wood, plastic, resin, carbon fiber, and composite. The frame  110  and/or gate  120  may be formed of the same or different materials,. Similarly the elements of the hinge  130  and lock  140  may be made from the same materials as the frame or from a different material. In some aspects, the frame  110  and/or gate  120  are electro-polished or electro-coated to improve corrosion resistance and surface texture. The frame and gate  110 ,  120  of the carabiners may be molded into the desired shape, may be powder-pressed, or shaped by bending alloy rods into the desired shape. Fine-tuning the curve and cross-section, forming the surface-texture  118 , through holes  119 , gate hinge hole  124 , or frame hinge hole  133  may be performed by machine stamping or machining. After the proper structure is achieved, these elements may be heat-treated to increase the strength thereof. The frame may be generally C-shaped, which in the present context equates generally to a loop missing a section, similar to the letter C. The frame may also encompasses any style or configuration of carabiner body, including at least oval, D-shaped, offset D-shaped, pear shaped, S-hook, double-gate or multi-gate, or any other style of quick-fastener. 
         [0025]    The frame  110  extends from the proximal end  111  to the distal end or nose  112 . The gap between the proximal end  111  and the distal end  112  of the frame  110  is the gate opening  113 , which is spanned by gate  120 . The proximal end  111  of the frame  100  includes a frame hinge hole  133  for connecting the hinge  130  with a hinge pin or rivet  132 . The nose  112  may include a notch (or a hook or fastener)  117  for securing a gate pin or other securing mechanism  123  at the distal end  122  of the gate  120 . The bend closest to the proximal end  111  is the crotch  115 . The bend closest to the distal end or nose  112  is the basket. The spine  114  is the long, sometimes reinforced section between the crotch  115  and the basket  116 . The spine  114  may be reinforced or thicker to provide extra strength or support. In some embodiments, the frame  110  may include a concave section between the crotch  115  and the spine  114 . 
         [0026]    The gate  120  comprises a proximal end  121  connected to the frame  110  by the hinge  130  and a distal end  122 . An inward force applied to the gate  120  will pivot the gate  120  about the hinge  130 , providing a gap between the distal end  122  of the gate  120  and the distal end  112  of the frame  110 , through which the interior cavity  101  can be accessed. An outward force applied from within the interior cavity  101  (such as by a rope or loop) presses the distal end  122  of the gate  120  against a notch or other feature of the nose  112 , transferring stress to the spine  114 . The gate  120  may be straight, concave, convex, or a combination of concave and convex. A convex gate provides a wider opening for access to the interior cavity  101  while a concave gate makes it easier to apply the gate opening force directly with a rope or loop. 
         [0027]    The hinge  130  comprises a hinge pin or rivet  132  inserted through a gate hinge hole  124  at the proximal end  121  of the gate  120  and the frame hinge hole  133  of the frame  110 . The gate  120  pivots about the hinge pin  132 , providing an opening for access to the interior cavity  101 . Alternatively hinge pin  112  can be a screw, a ball-and-socket joint, or any other pivotable attachment mechanism. Hinge  130  may also include a hinge spring  131  (not shown). Hinge spring  131  may be either a housed spring or cantilevered spring. A housed spring and piston requires a hollow cavity in the gate member, but cantilevered springs may be more cost-effective and stronger. Hinge spring  131  applies a force to return gate  120  to its default position. In most cases, the default position is a closed gate  120 , but in some specific instances, a default open gate  120  may be preferable. In alternate instances, the hinge may open inward, outward, or laterally. 
         [0028]      FIGS. 5-6  depict an exemplary cushioned carabiner frame  110  including a cushion layer  150  attached to the frame  110 . The cushion layer  150  may be molded directly over the frame  110 . In some instances, an adhesive may be applied between the frame  110  and the cushion layer  150  to improve the connection and durability of the carabiner  100 . 
         [0029]    In  FIGS. 5 and 6 , a single continuous cushion layer  150  is applied to the entire external surface  102  of the frame  110 , leaving the internal surface  103  exposed. This configuration cushions the carabiner clip from most angles without interfering with gate or lock movement. Additionally the exposed internal surface  103  retains the benefits of the durable metal (or other material) surface, including durability and low friction for ropes. It should be understood that in other embodiments, the cushion layer  150  may coat both the external surface  103  and the internal surface  102 . In still other embodiment, only the internal surface  103  is covered by a cushion layer  150 , while the external surface  102  remains exposed. A fully cushioned carabiner frame  110  or internally cushioned carabiner frame may be preferable to avoid leaving scratches or marks or simply to reduce clanging between metal pieces during movement. 
         [0030]    The cushion layer  150  may be manufactured from silicon, rubber, synthetic rubber, plastic, plastic alternatives, fabric, plant matter, paper, recycled materials, cellulose, bioisoprene, resin, or any other material. It may be preferable to injection-mold the cushion layer  150  around the frame  110  or gate  120 . In some instances, the carabiner frame  110  and the cushion-layer  150  may be co-molded through a dual-injection process, quickly and reliably producing a 2-material product. 
         [0031]    In some instances, the carabiner frame and cushion layer  150  may provide additional benefits, beyond impact-absorption and noise-dampening. The cushion layer  150  or carabiner frame  110  may be made of conductive materials, and as a weight applied to the carabiner  100  slightly elongates the frame  110 , the conductive cushion-layer  150  or the conductive carabiner frame  110  functions as a strain gauge, reading the change in electrical properties (resistance, resistivity, conductivity) and translating that change of state to estimate the load force. The estimated load force or the electrical properties changes may be transmitted to or detected by an outside computer. The conversion may occur outside of the carabiner  100 . In another embodiment, the cushion layer is intentionally formed of an insulating layer to prevent electrical conductivity, even if the underlying carabiner frame is made of a conductive material. 
         [0032]    Alternatively the cushion layer may be formed of a material that measures G-force, and once a certain G-force level is experienced, the cushion layer or a part thereof changes color. In some instances, this G-force cushion layer provides additional security and confidence by affirmatively indicating when a significant impact renders a carabiner unreliable for future use. 
         [0033]    Returning now to  FIGS. 3 and 4 , carabiner frames  110  similar to those depicted in  FIGS. 5 and 6  are shown without the cushion layer  150 . The frame  110  includes a surface texture or routing  118  and through holes  119  to increase the connection between frame  110  and cushion layer  150 . The surface texture increases the contact area and the “grip” between the frame  110  and the cushion layer significantly, and the through holes  119  allow an injection-molded cushion layer  150  to flow through the frame  110 , creating loops through the frame that further secure the cushion layer  150  in place and prevent peeling and prolonging the useful life of the carabiner. Placing through holes  119  at or near the various curved segments of the carabiner clip improves adhesion near those points. In the present embodiment,  3  through holes  119  pass through the frame within the surface routing  118 . Two of the through holes are located on opposite sides of the crotch, while the third through-hole is located between the nose  112  and the basket  116 . It should be noted that through-holes  119  reduce the strength of the frame  110  in the area immediately surrounding the through-hole, so through-holes should not be placed in high-strain areas if avoidable. In some embodiments, through-holes should not be included along the spine. 
         [0034]    As shown in  FIGS. 7-9 , some carabiners may include a lock  140  to secure the gate  120  relative to the frame  110 . The lock  140  ensures that gate  120  will remain closed until intentionally opened, and reduces the risk to health, life, and property. The lock of  FIGS. 7-9  is a screw-type lock, which includes a screw-type rotating fastener, which can be rotated multiple times about the gate  120 , forming a rigid sleeve that covers both a portion of the gate  120  and a portion of the frame  110  to strengthen the closed loop. Alternately, some twist-type gate locks require that the gate element  140  be pressed against a lock spring (not shown), rotated about the gate  120 , and then a pressure applied to the gate  120  will cause the gate  120  to pivot about hinge  130 . Other types of gate locks may include ball-lock mechanisms and additional latches or supports. 
         [0035]    As shown in  FIG. 12 , an alternate embodiment of the present invention may include a double crotch cushioned carabiner frame, including a first crotch  115   a  and a second crotch  115   b.  The two separate crotches  115   a,    115   b  enable the carabiner frame  110  to secure two ropes or loops simultaneously, minimizing friction and tangling between the two ropes with the two discrete crotches  115   a,    115 . One of ordinary skill in the art would understand that a multi-crotch cushioned carabiner frame could include more than two crotches without departing from the present invention. Additionally a further alternate embodiment not shown includes a multi-basket, including more than one basket  111   a,    111   b.  In some instances a carabiner may include multiple baskets  111   a,    111   b  and multiple crotches  115   a,    115   b.  Each crotch may be open to the interior of the carabiner clip or may be wholly looped by a reinforced element. The multiple crotch and multiple basket embodiments require more complex surface texture or routing  118  and potentially additional through-holes  119  to secure the cushion layer  150  to the frame  110 . 
         [0036]    Although various aspects are herein disclosed in the context of certain preferred embodiments, implementations, and examples, it will be understood by those skilled in the art that the present invention extends beyond the specifically disclosed embodiments to other alternative embodiments and/or uses of the inventive aspects and obvious modifications and equivalents thereof. In addition, while a number of variations of the aspects have been noted, other modifications, which are within their scope, will be readily apparent to those of skill in the art based upon this disclosure. It should be also understood that the scope this disclosure includes the various combinations or sub-combinations of the specific features and aspects of the embodiments disclosed herein, such that the various features, modes of implementation and operation, and aspects of the disclosed subject matter may be combined with or substituted for one another. Thus, it is intended that the scope of the present invention herein disclosed should not be limited by the particular disclosed embodiments or implementations described above, but should be determined only by a fair reading of the claims. 
         [0037]    Similarly, this method of disclosure, is not to be interpreted as reflecting an intention that any claim require more features than are expressly recited in that claim. Rather, as the following claims reflect, inventive aspects lie in a combination of fewer than all features of any single foregoing disclosed embodiment. Thus, the claims following the Detailed Description are hereby expressly incorporated into this Detailed Description, with each claim standing on its own as a separate embodiment.

Technology Classification (CPC): 4