Patent Description:
As is known in the art, there exist various safety devices and arrangements that can be worn by or attached to a user to ensure the wearer's safety in certain situations. Such mechanisms come in many forms, including, but not limited to, harnesses and safety belts. Full body harnesses are widely used for lifting and lowering individuals in dangerous situations and as a primary component in a personal fall arrest system. Examples for such harnesses are disclosed in <CIT>, <CIT>, and <CIT>. These harnesses can also be used for work positioning, travel restriction, ladder climbing, rescue retrieval, and evacuation. While these harnesses are used mainly in an industrial setting, and particularly the construction industry where the likelihood and danger of falls from heights is both numerous and significant, a full body harness can be used in various other applications in which total suspension and support of the body must be ensured, either expectedly or unexpectedly.

While there are many variations in full body harness construction, all typically include a plurality of elongate straps that are combined together to fit around a user's body. In some embodiments or aspects, a full body harness may have an attachment point (D-ring) typically positioned in a central portion of the user's back, and a plurality of straps routed around predetermined portions of the user's body in such a manner as to hold or suspend the user in the event of a fall.

Full body harnesses, when used in a personal fall arrest system, must always be used with an energy absorbing element. In some embodiments or aspects, the energy absorbing element may be a self-retracting lanyard (SRL), and in other embodiments or aspects may include a lanyard or a rope grab. The SRL is attached at one end to an anchor point and at its other end to a line directly connected to the user. The SRL is configured to activate once the user has begun to fall to arrest the fall soon enough to prevent injury to the user. Typically, an SRL has a housing with a rotatable drum having a line wound about the drum and a braking mechanism for controlling the rotation of the drum. The drum can rotate in a first direction to unwind (or "pay out") the line from the housing when a certain level of tension is deliberately applied. When tension is reduced or released, the drum can slowly rotate in a reverse direction, thereby causing the line to retract or rewind onto the drum. The braking mechanism is configured for slowing down and stopping the rotation of the drum when the line unwinds too rapidly. For example, the braking mechanism may be activated to brake the rotation of the drum when the rotation speed exceeds a predetermined velocity. A sudden line payout at a speed that exceeds normal payout is an indication that the user has experienced a fall that needs to be stopped or arrested. Should such an unintentional, accidental fall commence, the braking mechanism in the housing of the SRL is configured to engage and stop the user from falling too far.

Many falls occur over the edge of a working surface, causing the line of the SRL to bend over the edge. In such situations, the line is not moved relative to the edge, thereby imparting the entire force of a fall on a single point in the line at the edge. If an energy absorbing element is not positioned between the user and the edge, there is a risk that the user will be exposed to dangerously high forces caused by a sudden deceleration of the user's body as the user's weight is supported by the harness and a line attaching the user to the anchor point. Some full body harnesses have an energy absorbing element permanently attached to the D-ring on the user's back. This design. However, is often bulky and can interfere with the user's mobility. It also adds additional weight that the user must carry at all times.

Accordingly, there is a need in the art for an improved harness that addresses certain drawbacks and deficiencies associated with known harnesses. For example, there is a need for an improved harness with an improved energy absorbing element associated with the harness. There is a further need in the art for an improved harness that can be easily and effectively worn by the user in a variety of work environments without compromising the user's ability to move and without adding additional weight that must be borne by the user. There is also a need for an improved harness with increased safety compliance at the worksite, and with more effective and safe support of the user in the event of a fall.

Generally, provided is an improved fall protection harness having an integrated energy absorbing element according to claim <NUM>. This improved harness can be easily and effectively worn by the user in a variety of work environments without compromising the user's ability to move and without adding significant weight that must be borne by the user. The improved harness does not only lead to increased safety compliance at the worksite, but also provides increased effectiveness to the personal fall protection system and a resulting increase in the safety of the user in the event of a fall.

Claims <NUM> to <NUM> describe advantageous further embodiments of the claimed improved harness.

The opening may be a slit formed at a substantially intermediate portion of at least one of the first shoulder strap and the second shoulder strap between the first end and the second end of the at least one of the first shoulder strap and the second shoulder strap. The tubular webbing may be made from a woven tubular material.

In other preferred and non-limiting embodiments or aspects, the at least two bound webbing components may be bound by an adhesive. The predetermined threshold may be in the range of about <NUM> (<NUM> lbs) to about <NUM> (<NUM>,<NUM> lbs). The first shoulder strap and the second shoulder strap may have a starting tear area at the rear portion where the pair of bound webbing components is unbound. The first shoulder strap and the second shoulder strap may have an ending tear point having a reinforced area configured to prevent separation of the at least two bound webbing components. The energy absorbing element may be located on an energy absorbing area at the rear portion of at least one of the first shoulder strap and the second shoulder strap.

In other preferred and non-limiting embodiments or aspects, at least one connector may be arranged on at least one of the plurality of straps and configured to facilitate removable attachment of the free floating ends of at least one of the plurality of straps. The connector may be at least one of the following: a clip, a buckle, a mating arrangement, an attachment structure, or any combination thereof. The first end of each leg strap may be adjustably attached to the second end by a connection mechanism that can adjust the length of each leg strap. The harness may have a chest strap having a first end and a second end removably attached to each other and configured to be free floating when detached from each other. The first end of the chest strap may be attached to the first shoulder strap and the second end of the chest strap may be attached to the second shoulder strap. The harness may have a back strap connecting a rear portion of at least one of the first shoulder strap and the second shoulder strap.

At least one connector may be arranged on at least one of the plurality of straps and configured to facilitate removable attachment of free floating ends of at least one of the plurality of straps. The connector may be at least one of the following: a clip, a buckle, a mating arrangement, an actuatable structure, or any combination thereof. The first end of each leg strap may be adjustably attached to the second end by a connection mechanism to adjust a length of each leg strap. The harness may have a chest strap having a first end and a second end removably attached to each other and configured to be free floating when detached from each other. The first end of the chest strap may be attached to the first shoulder strap and the second end of the chest strap may be attached to the second shoulder strap.

These and other features and characteristics of the present disclosure, as well as the methods of operation and functions of the related elements of structures and the combination of parts and economies of manufacture, will become more apparent upon consideration of the following description and the appended claims with reference to the accompanying drawings, all of which form a part of this specification, wherein like reference numerals designate corresponding parts in the various figures.

For purposes of the description hereinafter, the terms "end", "upper", "lower", "right", "left", "vertical", "horizontal", "top", "bottom", "lateral", "longitudinal" and derivatives thereof shall relate to the invention as it is oriented in the drawing figures. However, it is to be understood that the invention may assume various alternative variations and step sequences, except where expressly specified to the contrary. It is also to be understood that the specific devices and processes illustrated in the attached drawings, and described in the following specification, are simply exemplary embodiments of the invention.

As used in the specification and the claims, the singular form of "a", "an", and "the" include plural referents unless the context clearly dictates otherwise. As used in the specification and the claims, the term "end" refers to the extreme distal portion or the area near or adjacent that portion. Unless otherwise specified, the use of the term "attach", "attachable", and/or "attachment" includes a permanent, semi-permanent, removable, or adjustable attaching arrangement. As used in the specification and the claims, the term "integrated", when used with reference to an energy absorbing element and any portion of a harness, means that an energy absorbing element is formed as a separate component or arrangement and can be combined in, on, or with at least a portion of a separately formed harness (e.g., at least one strap or portion of a strap of the harness), such that the two components together constitute a whole. Therefore, the terms "therewith", "therein", and "thereon" are used interchangeably in the context of the present description. As used in the specification and the claims, the term "substantially parallel" means a relative angle as between two objects (if extended to theoretical intersection), such as elongated objects and including reference lines, that is from <NUM>° to <NUM>°, or from <NUM>° to <NUM>°, or from <NUM>° to <NUM>°, or from <NUM>° to <NUM>°, or from <NUM>° to <NUM>°, or from <NUM>° to <NUM>°, or from <NUM>° to <NUM>°, inclusive of the recited values.

As used in the specification and the claims, all ranges or ratios disclosed herein are to be understood to encompass any and all subranges or sub-ratios subsumed therein. For aspect or embodiment, a stated range or ratio of " <NUM> to <NUM>" should be considered to include any and all subranges between (and inclusive of) the minimum value of <NUM> and the maximum value of <NUM>; that is, all sub-ranges or sub-ratios beginning with a minimum value of <NUM> or more and ending with a maximum value of <NUM> or less, such as but not limited to, <NUM> to <NUM>, <NUM> to <NUM>, and <NUM> to <NUM>.

In various preferred and non-limiting embodiments or aspects, and with reference to <FIG>, the present disclosure is directed to a harness <NUM> used in a fall protection system. As discussed herein, the harness <NUM> has at least one structural energy absorbing element integrated therewith and made from a tearable webbing material configured for absorbing energy during a fall event. In various preferred and non-limiting embodiments or aspects, the harness <NUM> may be used in combination with a supplementary energy absorbing element, such as a self-retracting lanyard (SRL) (not shown), to provide additional energy absorption during a fall event.

With continued reference to <FIG>, the harness <NUM> has at least two leg straps <NUM> configured to attach around a user's legs below a user's groin area. When attached, the leg straps <NUM> loop around or encircle each of the user's legs. Each leg strap <NUM> has a first end 102a that is removably attachable to a second end 102b via a connector <NUM>. In some preferred and non-limiting embodiments or aspects, the connector <NUM> may be a clip, a buckle, a mating arrangement, an actuatable structure, or the like. The connector <NUM> permits removable attachment of the first end 102a to the second end 102b of each leg strap <NUM>. In this manner, the first and second ends 102a, 102b of the leg straps <NUM> are configured to be removably attached to each other and configured to be free floating when detached from each other. In some preferred and non-limiting embodiments or aspects, at least one connector <NUM> and/or the leg strap <NUM> may have at least one connection mechanism <NUM> configured for adjusting the length of each leg strap <NUM>. In this manner, the at least one connection mechanism <NUM> adjusts a distance between the first end 102a and the second end 102b such that each leg strap <NUM> may be adjusted to fit comfortably around the user's legs. Each leg strap <NUM> may be formed from a substantially flat webbing material typically used in harness construction.

In various preferred and non-limiting embodiments or aspects of the present disclosure, the leg straps <NUM> (or, indeed, any of the straps in the harness <NUM>) may be linear lengths of material, folded straps that form loops with the at least one connector <NUM> at the first end 102a and/or the second end 102b, or the like. For example, as shown in <FIG>, the connector <NUM> may have a first portion 104a that is non-adjustably attached to the first end 102a of at least one leg strap <NUM>, while a second portion 104b of the connector <NUM> is adjustably secured at the second end 102b of at least one leg strap <NUM> through a loop of the material that makes up the leg strap <NUM>. Therefore, in such an arrangement, the second portion 104b of the connector <NUM> and the loop of material that makes up the leg strap <NUM> at the second end 102b defines the at least one connection mechanism <NUM> for adjusting a length of the leg strap <NUM>. It should be noted that the position of the connection mechanism <NUM> may be reversed such that the second portion 104b of the connector <NUM> is provided on the first end 102a of the leg strap <NUM>. At least one leg strap <NUM> may have padding (not shown) for increasing the user's comfort while wearing the harness <NUM>.

With continued reference to <FIG>, each leg strap <NUM> is connected to a belt strap <NUM> at a substantially intermediate portion 102c of the leg strap <NUM> between the first end 102a and the second end 102b. For example, each leg strap <NUM> may be connected to the belt strap <NUM>. In some preferred and non-limiting embodiments or aspects, the substantially intermediate portion 102c of the leg strap <NUM> may be directly and non-movably connected to the belt strap <NUM>, such as being sewn directly to the belt strap <NUM>. In other preferred and non-limiting embodiments or aspects, the substantially intermediate portion 102c of each leg strap <NUM> may be connected to the rear end of the belt strap <NUM> by a connection strap (not shown) to allow the substantially intermediate portion 102c of the leg strap <NUM> to slidably move along a front portion of the leg strap <NUM>. Accordingly, the position of the leg straps <NUM> may be adjusted relative to the belt strap <NUM> to increase the user's comfort while wearing the harness <NUM>.

The belt strap <NUM> is configured to encircle at least a portion of the user's torso. The belt strap <NUM> has a first end 110a that is attached to a first portion of a shoulder strap <NUM> and a second end 110b that is attached to a second portion of the shoulder strap <NUM>. The first end 110a and the second end 110b may be removably or non-removably attachable to the shoulder strap <NUM>. In some embodiments or aspects, at least one of the first end 110a and the second end 110b may be attachable to the shoulder strap <NUM> via a connector similar to the connector <NUM> described herein with reference to the leg straps <NUM>. In some preferred and non-limiting embodiments or aspects, the belt strap <NUM> may have at least one connection mechanism <NUM> configured for adjusting the length of the belt strap <NUM>. In this manner, the at least one connection mechanism <NUM> adjusts a distance between the first end 110a and the second end 110b such that the belt strap <NUM> may be adjusted to fit comfortably around the user's torso. One or more handle connection members, and other handling and/or connectors <NUM> may be provided on at least a portion of the belt strap <NUM>. The belt strap <NUM> may have padding (not shown) for increasing the user's comfort while wearing the harness <NUM>. The belt strap <NUM> may be formed from a substantially flat webbing material typically used in harness construction.

With continued reference to <FIG>, the harness <NUM> further has the shoulder strap <NUM> configured to extend over at least a portion of the user's shoulders. The shoulder strap <NUM> may have a first shoulder strap 126a and a second shoulder strap 126b arranged to overlap one another in an X-shaped configuration. In some preferred and non-limiting embodiments or aspects, the shoulder strap <NUM> may have at least one shoulder pad <NUM> having one or more openings through which the first shoulder strap 126a and the second shoulder strap 126b can be arranged to maintain the first shoulder strap 126a and the second shoulder strap 126b in the X-shaped configuration.

With specific reference to <FIG>, the first shoulder strap 126a has a first end 127a that is connected to the second end 110b of the belt strap <NUM>. The first end 127a of the first shoulder strap 126a may be removably or non-removably attachable to the second end 110b of the belt strap <NUM>. In some preferred and non-limiting embodiments or aspects, the first end 127a of the first shoulder strap 126a may be attached to the second end 110b of the belt strap <NUM> via a connector similar to the connector <NUM> described herein with reference to the leg straps <NUM>. The first shoulder strap 126a further has a second end 127b that is connected to one of the two leg straps <NUM>. In some preferred and non-limiting embodiments or aspects, the second end 127b of the first shoulder strap 126a is connected to the leg strap <NUM> proximate to the second end 102b of the leg strap <NUM>, such as by being sewn directly to the leg strap <NUM>. The first shoulder strap 126a may have at least one loop <NUM> through which the first end 110a of the belt strap <NUM> may be passed. At least a portion of the first shoulder strap 126a may be formed from a substantially flat webbing material typically used in harness construction.

With continued reference to <FIG>, the second shoulder strap 126b has a first end 129a that is connected to the first end 110a of the belt strap <NUM>. The first end 129a of the second shoulder strap 126b may be removably or non-removably attachable to first end 110a of the belt strap <NUM>. In some embodiments or aspects, the first end 129a of the second shoulder strap 126b may be attached to the first end 110a of the belt strap <NUM> via a connector similar to the connector <NUM> described herein with reference to the leg straps <NUM>. The second shoulder strap 126b further has a second end 129b that is connected to the other of the two leg straps <NUM>. In some preferred and non-limiting embodiments or aspects, the second end 129b of the second shoulder strap 126b is connected to the leg strap <NUM> proximate to the second end 102b of the leg strap <NUM>, such as by being sewn directly to the leg strap <NUM>. The second shoulder strap 126b may have at least one loop <NUM> through which the second end 110b of the belt strap <NUM> may be passed. At least a portion of the second shoulder strap 126b may be formed from a substantially flat webbing material typically used in harness construction.

As shown in <FIG>, the harness <NUM> may have a back strap <NUM> connecting a substantially intermediate portion of the first shoulder strap 126a between its first end 127a and second end 127b with a substantially intermediate portion of the second shoulder strap 126b between its first end 129a and second end 129b. A position of the back strap <NUM> may be adjustable along a longitudinal direction of each the first shoulder strap 126a and the second shoulder strap 126b, such as by sliding the back strap <NUM> along the first shoulder strap 126a and/or the second shoulder strap 126b.

The harness <NUM> further may have a chest strap <NUM> having a first end 132a removably connectable to a second end 132b. The first end 132a of the chest strap <NUM> may be positioned proximate to the first end 127a of the first shoulder strap 126a, while the second end 132b of the chest strap <NUM> may be positioned proximate to the first end 129a of the second shoulder strap 126b. The first end 132a of the chest strap <NUM> is removably attachable to the second end 132b via a connector, similar to the connector <NUM> described herein with reference to the leg straps <NUM>. In some preferred and non-limiting embodiments or aspects, the connector <NUM> may be a clip, a buckle, a mating arrangement, an actuatable structure, or the like. In this manner, the first and second ends 132a, 132b of the chest strap <NUM> are configured to be removably attached to each other and configured to be free floating when detached from each other. In some preferred and non-limiting embodiments or aspects, at least one of the back strap <NUM> and the chest strap <NUM> may have at least one connection mechanism, such as the connection mechanism <NUM> described herein with reference to the leg straps <NUM>. The connection mechanism <NUM> is configured for adjusting the length of the back strap <NUM> and/or the chest strap <NUM>. The back strap <NUM> and the chest strap <NUM> may be formed from a substantially flat webbing material typically used in harness construction.

With reference to <FIG>, the shoulder strap <NUM> has an anchor element, such as a D-ring <NUM>, for connecting at least a portion of the shoulder strap <NUM> to a line connected to an anchor point. In some preferred and non-limiting embodiments or aspects, at least a portion of the first shoulder strap 126a and the second shoulder strap 126b is looped around or otherwise permanently attached to the D-ring <NUM>. The D-ring <NUM> has a frame <NUM> defining at least one opening through which the first shoulder strap 126a and the second shoulder strap 126b may be looped around. In some preferred and non-limiting embodiments or aspects, the frame <NUM> of the D-ring <NUM> has a first opening <NUM> through which the first shoulder strap 126a and the second shoulder strap 126b extend. The D-ring further has a second opening <NUM> which may be used to secure the clip, such as a carabiner, of a lanyard or other rope or line between the harness <NUM> and the anchor point (or secure other items to the harness <NUM>).

The shoulder strap <NUM> has an energy absorbing element integrated therewith. The first shoulder strap 126a and the second shoulder strap 126b are constructed from a tearable webbing material, such as an energy absorbing tear tape that is encased within a tubular webbing. With reference to <FIG>, both the first shoulder strap 126a and the second shoulder strap 126b are made from a substantially flat webbing material <NUM> that is encased within a tubular webbing <NUM>. The substantially flat webbing material <NUM> is completely encased within the tubular webbing <NUM>, except at a substantially intermediate portion of the first shoulder strap 126a and the second shoulder strap 126b, where at least a portion of the substantially flat webbing material <NUM> is exposed (and exit) from the tubular webbing <NUM>. Of course, this exposure or exit point or area may be at any point along the length of the first shoulder strap 126a and the second shoulder strap 126b.

The substantially flat webbing material <NUM> is exposed from the tubular webbing <NUM> through an opening <NUM> in the tubular webbing <NUM> in an area where the substantially flat webbing material <NUM> is connected to the D-ring <NUM>. As described herein, a first portion of the substantially flat webbing material <NUM> from each of the first shoulder strap 126a and the second shoulder strap 126b is connected directly to the D-ring <NUM>, while a second portion of the substantially flat webbing material <NUM> bypasses the D-ring <NUM>. In this manner, the harness <NUM> does not differ externally from a conventional harness without the energy absorbing element, but incorporates the beneficial energy absorption element integrated into the harness <NUM>.

With reference to <FIG>, the first shoulder strap 126a is illustrated. The second shoulder strap 126b is omitted for simplicity of illustration. While the illustration of the second shoulder strap 126b is omitted from <FIG>, construction and operation of the second shoulder strap 126b is identical to that of the first shoulder strap 126a in the embodiment or aspect where both shoulder straps 126a, 126b incorporate the tubular webbing <NUM> and/or energy absorbing element. Each of the first shoulder strap 126a and a second shoulder strap 126b have the tubular webbing <NUM> arranged to overlap one another in an X-shaped configuration. The tubular webbing <NUM> of the first shoulder strap 126a has a first end that corresponds with the first end 127a of the first shoulder strap 126a (shown in <FIG>). The first end of the tubular webbing <NUM> is connected to the second end 110b of the belt strap <NUM> in a removably or non-removably attachable manner. The first end of the tubular webbing <NUM> is attachable to the second end 110b of the belt strap <NUM> via a connector similar to the connector <NUM> described herein with reference to the leg straps <NUM>. The tubular webbing <NUM> further has a second end that corresponds to the second end 127b of the first shoulder strap 126a (shown in <FIG>). The second end of the tubular webbing <NUM> may be connected to one of the two leg straps <NUM> in a removably or non-removably attachable manner. The tubular webbing <NUM> may be formed from webbing material that is woven into a tubular shape, or from flat webbing material wherein opposite lateral ends of the substantially flat webbing material are connected together to form the tubular shape of the tubular webbing <NUM>.

In various examples, the tubular webbing <NUM> may have an internal diameter of about <NUM> (<NUM> inches) to about <NUM> (<NUM> inches). In various embodiments or aspects, a longitudinal length of the tubular webbing <NUM> may be between about <NUM> (<NUM> inches) to about <NUM> (<NUM> inches). The opening <NUM> in the tubular webbing <NUM> may be formed at a substantially intermediate point between the first end 127a and the second end 127b of the first shoulder strap 126a (and/or the second shoulder strap 126b). In some preferred and non-limiting embodiments or aspects, the opening <NUM> may be formed at a rear portion of the harness <NUM> at an upper portion of a user's back. In this manner, the opening <NUM> allows the substantially flat webbing material <NUM> to be exposed such that the substantially flat webbing material <NUM> may be connected to the D-ring <NUM>. The opening <NUM> may be formed as a slit in the tubular webbing <NUM> having a length between about <NUM> (<NUM> inches) to about <NUM> (<NUM> inches). In one preferred and non-limiting embodiment, and upon activation of the energy absorbing element, e.g., the flat webbing material <NUM>, at least a portion of the energy absorbing element is configured to exit through the opening <NUM> of the tubular webbing <NUM> upon tearing, thereby facilitating the complete (if necessary) separation of the flat webbing material <NUM>. Further, it is envisioned that the opening <NUM> may be reinforced wholly or partially around its edges to ensure that the tubular webbing <NUM> does not rip or tear during a fall event.

With continued reference to <FIG>, the substantially flat webbing material <NUM> of the first shoulder strap 126a has two webbing components 146a, 146b (which may be load-bearing webbing components) that are woven together by binder threads <NUM>. In some embodiments or aspects, the webbing material <NUM> may have a plurality of load-bearing webbing components. The webbing components 146a, 146b may each be typically made from a two ply webbing material constructed from high tenacity polyester or nylon yarns. Each webbing component 146a, 146b may have a face ply and a back ply. The webbing components 146a, 146b may be superimposed over one another such that the back ply of one of the webbing components 146a, 146b is positioned over the face ply of the other of the webbing components 146a, 146b. The webbing components 146a, 146b and the binder threads <NUM> are woven together to constitute a single-piece webbing material, i.e., the first shoulder strap 126a and the second shoulder strap 126b. While the present disclosure describes binder threads <NUM> as a means of integrally bonding the webbing components 146a, 146b together, other suitable bonding means, such as hook-and-loop fasteners, adhesives, or other energy absorbing materials may also be used, either individually or in combination with the binder threads <NUM>.

When the energy absorbing element is activated, such as during a fall event, the binder threads <NUM> are configured to be torn upon experiencing a force in excess of a predetermined force, thereby allowing the two webbing components 146a, 146b to tear apart from each other, such as shown in <FIG>. In some embodiments or aspects, the predetermined force (load) may be in the range of about <NUM> (<NUM> lbs) to about <NUM> (<NUM>,<NUM> lbs). The binder threads <NUM> are configured to absorb energy (force) of a user falling during a fall event by fracturing (or tearing/separating) and allowing the webbing components 146a, 146b to separate from each other. The tearing of the binder threads <NUM> may be initiated by a minimum predetermined force (load), such as about <NUM> (<NUM> lbs). The tearing of the binder threads <NUM>, and a consequent separation of the webbing components 146a, 146b continues as long as the force on the harness <NUM> exceeds the minimum predetermined force and ends when either (<NUM>) the webbing components 146a, 146b reach an ending point; or (<NUM>) the force reduces to a point below the minimum predetermined force. In various embodiments or aspects, the shoulder strap <NUM> may be configured to tear the webbing components 146a, 146b apart from each other due to breaking of the binder threads <NUM> at a constant force. The minimum predetermined force (load) required to break the binder threads <NUM> may be configurable by increasing or decreasing the density of the binder threads <NUM> per unit area, increasing or decreasing the width of the shoulder strap <NUM>, increasing or decreasing the density of the binder threads <NUM> along a longitudinal length and/or a lateral length of the shoulder strap <NUM>, and/or selecting a type of thread having specified strength characteristics.

As discussed above, and in another preferred and non-limiting embodiment or aspect, the webbing components 146a, 146b may be bound together by an adhesive, such as glue, that separates when reaching the minimum predetermined force or load. It is recognized that these adhesives may be specifically formulated to meet the separation requirements at the minimum predetermined force or load.

With reference to <FIG>, the binder threads <NUM> may extend through at least a portion of a thickness of at least one of the webbing components 146a, 146b. For example, the binder threads <NUM> may extend between the face ply and the back ply of each of the webbing components 146a, 146b. In some embodiments or aspects, such as shown in <FIG>, the binder threads <NUM> extend though the entire thickness of each of the webbing components 146a, 146b. With reference to <FIG>, the binder threads <NUM> may be woven in two or more rows <NUM> extending along a longitudinal length and/or a lateral length of the webbing components 146a, 146b. In various preferred and non-limiting embodiments or aspects, the rows <NUM> may be substantially parallel to each other, or intersect at least once with each other along the longitudinal length and/or the lateral length of the webbing components 146a, 146b. With reference to <FIG>, the binder threads <NUM> may be arranged in a plurality of thread groups <NUM> arranged in a pattern on the webbing components 146a, 146b. In some preferred and non-limiting embodiments or aspects, the density of thread groups <NUM> may be constant along the longitudinal length and/or the lateral length of the webbing components 146a, 146b. In this manner, the webbing components 146a, 146b will separate from one another due to breaking of the binder threads <NUM> at a constant rate at a given force that exceeds the minimum predetermined force. In other preferred and non-limiting embodiments or aspects, the density of thread groups <NUM> may vary along the longitudinal length and/or the lateral length of the webbing components 146a, 146b, such as by increasing or decreasing the density of the thread groups <NUM>. Accordingly, the webbing components 146a, 146a will separate from one another due to breaking of the binder threads <NUM> at an increasing or decreasing rate at a given force that exceeds the minimum predetermined force. The arrangement of the thread groups <NUM> may be selected to optimize the tear-away force required to break the binder threads <NUM> (or adhesive) during separation of the webbing components 146a, 146b from each other. In various preferred and non-limiting embodiments or aspects, the binder threads <NUM> extend continuously between the webbing components 146a, 146b in a sinusoidal manner. The binder threads <NUM> may be made from high tenacity polyester yarns, nylon, or other suitable materials. The tensile strength of the binder threads <NUM> is desirably selected to be less than that of the webbing components 146a, 146b to allow the binder threads <NUM> to tear without tearing the webbing components 146a, 146b.

With reference to <FIG>, the first shoulder strap 126a may have a starting tear point <NUM> at which the two webbing components 146a, 146b are not bound by the binder threads <NUM>. The starting tear point <NUM> may be defined at a substantially intermediate portion of the first shoulder strap 126a between the first end 127a and the second end 127b. After the starting tear point <NUM>, the webbing components 146a, 146b are integrally woven together. With reference to <FIG>, as the user falls during a fall event, the binder threads <NUM> start to fracture (or tear) at the starting tear point <NUM> and continue tearing along the longitudinal length of an energy absorbing area <NUM> of the shoulder strap <NUM> that ties the webbing components 146a, 146b with the binder threads <NUM>. The binder threads <NUM> are configured to tear successively along the longitudinal length of the bound absorbing area <NUM> beginning from the starting tear point <NUM>. The successive tearing of the binder threads <NUM> absorbs energy of the fall, thereby safely decelerating the user and reducing the shock transferred to the user's body as the user's weight is borne by the harness. Further, at least a portion of the webbing components 146a, 146b exit from the tubular webbing <NUM> through the opening <NUM>.

With continued reference to <FIG>, the first shoulder strap 126a may have an ending tear point <NUM> at an end of the energy absorbing area <NUM>. The ending tear point <NUM> may have a reinforced area <NUM>, such as by additional stitching, to prevent further tearing of the webbing components 146a, 146b. Once activated, the two webbing components 146a, 146b support the user's weight, such as with one of the webbing components 146a, 146b being connected to the D-ring <NUM>, and the other of the two webbing components 146a, 146b supporting the user's shoulders. The tearing of the two webbing components 146a, 146b due to breaking of the binder threads <NUM> may end prior to the ending tear point <NUM> if the force on the harness is reduced below the minimum predetermined force necessary to tear the binder threads <NUM>.

The shoulder strap <NUM> having an energy absorbing element integrated therewith, such as the two webbing components 146a, 146b bound by binding threads <NUM>, reduces the risk of misuse, especially in leading edge applications where the user may incorrectly attach an integrated energy absorbing element to a conventional harness. A harness <NUM> having such a shoulder strap <NUM> eliminates the need for a structural back-up strap as the tear tape maintains the static strength of structural webbing at full elongation (end of deployment shown in FIG. In this manner, the harness <NUM> does not differ externally from a conventional harness without the energy absorbing element, but incorporates the beneficial energy absorption element integrated into the harness <NUM>.

Claim 1:
A fall protection harness (<NUM>) comprising:
a first shoulder strap (126a) and a second shoulder strap (126b) each comprising a tearable fold-free flat webbing material (<NUM>) having a first webbing component (146a) bound to a second webbing component (146b) along at least one energy absorbing area (<NUM>) between a starting tear point (<NUM>) and an ending tear point (<NUM>), the first webbing component (146a) and the second webbing component (146b) being at least partially encased within a tubular webbing (<NUM>), wherein the tubular webbing (<NUM>) comprises an opening (<NUM>) and wherein at least a portion of the tearable fold-free flat webbing material (<NUM>) of each of the first shoulder strap (126a) and the second shoulder strap (126b) is exposed from the tubular webbing (<NUM>) through the opening (<NUM>); and
an anchor element (<NUM>) connected to the first webbing component (146a) of each of the first shoulder strap (126a) and the second shoulder strap (126b) at an unbound portion between adjacent energy absorbing areas (<NUM>) of the first webbing component (146a) and the second webbing component (146b),
wherein the first webbing component (146a) of each of the first shoulder strap (126a) and the second shoulder strap (126b) is configured to tear away from the second webbing component (146b) upon exposure to a force in excess of a predetermined threshold.