Patent Description:
According to the invention, there is provided a lanyard as defined by the appended claims.

Additional features and advantages will be set forth in the detailed description, which follows, and, in part, will be readily apparent to those skilled in the art from the description or recognized by practicing the embodiments as described in the written description included, as well as the appended drawings. It is to be understood that both the foregoing general description and the following detailed description are exemplary.

The accompanying drawings are included to provide further understanding and are incorporated in and constitute a part of this specification. The drawings illustrate one or more embodiments and, together with the description, serve to explain principles and operation of the various embodiments.

In order to better understand the subject matter that is disclosed herein and to exemplify how it may be carried out in practice, embodiments will now be described, by way of non-limiting examples only, with reference to the accompanying drawings, in which:.

Referring generally to the figures, various embodiments of a lanyard are shown. Lanyards are used as a safety measure to secure tools/equipment to an anchor point, for example, while working at height. To enhance safety, a lanyard may couple to tools, protective equipment, tool batteries, other construction devices/equipment, etc. and tether them when operating the tools at height. Various regulations (e.g., OSHA regulations) may require a lanyard when an operator uses a tool at height. When a tool is dropped at height, the lanyard couples the tool to an anchor point and prevents the tool from dropping further than a distance provided by the lanyard. This prevents a safety hazard and also protects the tool from the damage that may be otherwise caused by the fall.

Applicant has developed an innovative locking/biasing mechanism that restricts movement of the lanyard spool. When the locking mechanism is in the locked position, the lanyard spool is biased from rotating unless a sufficient pulling force is exerted on the cord, in which case the locking mechanism disengages from the lanyard spool. This disengagement functionality permits the lanyard cord to be extended without requiring the user to directly interface with and actuate the locking mechanism. When the locking mechanism is in the unlocked position, the lanyard spool is permitted to rotate without interference from the locking mechanism. The locking mechanism includes locking components that bias the locking mechanism to remain stationary when in the locked and the unlocked positions.

Referring to <FIG>, various aspects of a device, shown as lanyard <NUM>, are shown. Lanyard <NUM> includes a first retractable coupling mechanism, shown as carabiner <NUM>, and a second fixed coupling mechanism, shown as carabiner <NUM>, coupled to housing <NUM>. Both carabiner <NUM> and carabiner <NUM> are coupled to housing <NUM>. Housing <NUM> includes an opening <NUM>. An elongate flexible structure, shown as cord <NUM>, has an inner end <NUM> coupled to spool <NUM> and an opposing outer end <NUM> extending out of opening <NUM>. Carabiner <NUM> is coupled to outer end <NUM> of cord <NUM>. Cord <NUM> is extendable and retractable from housing <NUM>, thereby reducing and increasing the distance that carabiner <NUM> may be separated from housing <NUM>. Carabiner <NUM> is coupled to housing <NUM> such that the carabiner <NUM> and housing <NUM> remain a relatively fixed distance from each other.

In use, carabiner <NUM> is coupled to items such as tools, protective equipment, tool batteries, other construction devices/equipment, etc. Carabiner <NUM> anchors lanyard <NUM> to an anchor point, such as a belt, scaffold, etc. If and when the item coupled to carabiner <NUM> is dropped, lanyard <NUM> anchors the item to the anchor point to which carabiner <NUM> is coupled.

Spool <NUM> is rotatably coupled to housing <NUM> (e.g., rotatably mounted within housing <NUM>) such that spool <NUM> rotates around axis <NUM> with respect to housing <NUM>. In a specific embodiment, spool <NUM> is a reel. An elongate structure, shown as cord <NUM>, is wound around spool <NUM>. As cord <NUM> is extracted from housing <NUM> through opening <NUM>, spool <NUM> rotates around axis <NUM> in a second rotational direction, shown as direction <NUM>. Spool <NUM> rotates in a first direction, opposite direction <NUM>, when the cord <NUM> to retract cord <NUM> within housing <NUM> and onto spool <NUM>. Retraction system <NUM> biases spool <NUM> opposite rotational direction <NUM>, thereby biasing cord <NUM> towards being retracted within housing <NUM> onto spool <NUM>. In a specific embodiment retraction system <NUM> includes a spring, such as a spiral spring. In a specific embodiment, retraction system <NUM> is coupled to spool <NUM> and retraction system <NUM> biases cord <NUM> to be rewound onto spool <NUM>. In a specific embodiment, arm <NUM> interfacing with spool <NUM> when arm <NUM> is in the locked position biases spool <NUM> from rotating, such as rotating in the direction opposite rotational direction <NUM>. In a specific embodiment, arm <NUM> is a shuttle that slides linearly with respect to housing <NUM>.

In another embodiment, the configuration of the lanyard is flipped and thus in the reverse arrangement. For example, as cord <NUM> is extracted from housing <NUM>, spool <NUM> rotates around axis <NUM> opposite rotational direction <NUM>, tooth <NUM> of arm are on the right side of arm <NUM>, and arm <NUM> is in the locked position when arm <NUM> is extending out the left-side of housing (from the perspective of <FIG>).

Arm <NUM> actuates along linear axis <NUM> such that when arm <NUM> is in the locked position (best shown <FIG>), a protrusion from arm <NUM>, shown as tooth <NUM>, interfaces with teeth <NUM> of spool <NUM>. When tooth <NUM> and teeth <NUM> interface, arm <NUM> resists spool <NUM> rotating in either direction <NUM> or opposite direction <NUM>. Stated another way, arm <NUM> interfaces with spool <NUM> when arm <NUM> is in the locked position to bias the spool <NUM> from rotating. When arm <NUM> is in the unlocked position (best shown <FIG>), tooth <NUM> of arm <NUM> does not interface with teeth <NUM> of spool <NUM>, so arm <NUM> no longer resists spool <NUM> rotating. In a specific embodiment, arm <NUM> is slideably coupled to housing <NUM> such that arm <NUM> actuates between the locked and unlocked position via arm <NUM> sliding with respect to housing <NUM>. In a specific embodiment, arm <NUM> includes body <NUM>, first end <NUM> of body <NUM>, and opposing second end <NUM> of body <NUM> opposite first end <NUM>.

A first biasing component, shown as a spring-biased ball <NUM>, and a second biasing component, also shown as a spring-biased ball <NUM>, selectively resist arm <NUM> actuating between the locked position (<FIG>) and the unlocked position (<FIG>). When arm <NUM> is in the locked position (<FIG>), spring-biased ball <NUM> interfaces with recess <NUM> and spring-biased ball <NUM> interfaces with recess <NUM>, thereby biasing arm <NUM> to remain in the locked position.

To actuate arm <NUM> from the locked position to the unlocked position, a user can exert a force on second end <NUM> of arm <NUM> sufficient to overcome the biasing forces of spring-biased ball <NUM> and spring-biased ball <NUM>. When sufficient force is exerted on second end <NUM> of arm <NUM>, arm <NUM> moves from the locked position (<FIG>) to the unlocked position (<FIG>) until first end <NUM> of arm <NUM> extends from opening <NUM> of housing <NUM> and second end <NUM> of arm <NUM> no longer extends from opening <NUM> of housing <NUM>. When arm <NUM> is in the unlocked position (<FIG>), spring-biased ball <NUM> interfaces with recess <NUM>, and spring-biased ball <NUM> interfaces with recess <NUM>, thereby biasing arm <NUM> to remain in the unlocked position.

In a specific embodiment, when arm <NUM> is in the locked position, first end <NUM> of arm <NUM> extends out of housing <NUM> and second end <NUM> does not extend out of housing <NUM>, and arm <NUM> interfaces with spool <NUM> to bias spool <NUM> from rotating when arm <NUM> is in the locked position. In a specific embodiment, when arm <NUM> is in the unlocked position, second end <NUM> extends out of housing <NUM> and first end <NUM> does not extend out of housing <NUM>, and arm <NUM> does not bias spool <NUM> from rotating when the arm <NUM> is in the unlocked position.

In a specific embodiment, arm <NUM> transitions from the locked position to the unlocked position in response to cord <NUM> receiving a pulling force (e.g., a force in direction <NUM>; see <FIG>) greater than a threshold amount of force (e.g., an amount of force sufficient to overcome the biasing forces of arm biasing system <NUM>). For example, when cord <NUM> receives the threshold amount of force, teeth <NUM> of spool <NUM> interface with tooth <NUM> to push arm <NUM> to the unlocked position (e.g., to the left as seen in <FIG> and <FIG>).

In another embodiment, when arm <NUM> is in the locked position then arm <NUM> extends from both ends of housing <NUM>, and when arm <NUM> is in the unlocked position then arm <NUM> extends from both ends of housing <NUM>.

Alternatively, exerting sufficient force on cord <NUM> actuates arm <NUM> from the locked position to the unlocked position. As a pulling force is exerted on cord <NUM> relative to housing <NUM>, cord <NUM> exerts a corresponding rotational force in direction <NUM> on spool <NUM>. When sufficient force is exerted on spool <NUM>, teeth <NUM> of spool <NUM> push tooth <NUM> of arm <NUM> to the left (from the perspective of <FIG>) along linear axis <NUM>. Thus, if sufficient pulling force is exerted on cord <NUM>, arm <NUM> will be actuated from the locked position (<FIG>).

In a specific embodiment, arm biasing system <NUM> includes first arm-biasing mechanism <NUM> and second arm-biasing mechanism <NUM>. Arm biasing system <NUM> biases arm <NUM> to remain in the locked position and arm biasing system <NUM> biases arm <NUM> to remain in the unlocked position. First arm-biasing mechanism <NUM> includes first spring-biased ball <NUM> and a first biasing element, shown as spring <NUM>, that biases first spring-biased ball <NUM> against arm <NUM>. Second arm-biasing mechanism <NUM> includes second spring-biased ball <NUM> and a second biasing element, shown as spring <NUM>, that biases second spring-biased ball <NUM> against arm <NUM>.

In a specific embodiment, each of first arm-biasing mechanism <NUM> and second arm-biasing mechanism <NUM> include a detent that interfaces with one of spring-biased ball <NUM>, <NUM>. In various embodiments, first arm-biasing mechanism <NUM> biases arm <NUM> to remain in the locked position, and second arm-biasing mechanism <NUM> biases arm <NUM> to remain in the unlocked position. In a specific embodiment, first arm-biasing mechanism <NUM> further biases arm <NUM> to remain in the unlocked position in addition to biasing arm <NUM> to remain in the locked position. In a specific embodiment, second arm-biasing mechanism <NUM> further biases arm <NUM> to remain in the locked position in addition to biasing arm <NUM> to remain in the unlocked position.

In an alternate embodiment, arm biasing system <NUM> only includes one of first arm-biasing mechanism <NUM> and second arm-biasing mechanism <NUM> (e.g., only one spring-biased ball <NUM> and only one spring-biased ball <NUM>).

In a specific embodiment, arm <NUM> includes a hard-stop, shown as lower protrusion <NUM>, that restricts the range of sliding motion by arm <NUM>. Lower protrusion <NUM> of arm <NUM> interfaces with left wall <NUM> and right wall <NUM> of housing <NUM>, to restrict arm <NUM> to positions between the locked position (<FIG>) and the unlocked position (<FIG>). In another embodiment arm <NUM> does not include lower protrusions <NUM> that interfaces left wall <NUM> and right wall <NUM> of housing <NUM>.

Referring to <FIG> and <FIG>, a lanyard <NUM> is shown according to an exemplary embodiment. Lanyard <NUM> is similar to lanyard <NUM> with the exception of the differences described.

Lanyard <NUM> includes a first locking component, shown as a spring-biased ball <NUM>, and a second locking component, shown as a spring-biased ball <NUM>. Spring-biased balls <NUM> and <NUM> operate to selectively resist movement of arm <NUM> along axis <NUM>. Arm <NUM> actuates along axis <NUM> with respect to housing <NUM> between a locked position (<FIG>) and an unlocked position, and spring-biased balls <NUM> and <NUM> retain arm <NUM> in the locked or unlocked position following selection of the position by the user.

When arm <NUM> is in the locked position (<FIG>), spring-biased ball <NUM> interfaces with recess <NUM> and spring-biased ball <NUM> interfaces with recess <NUM>. and In this position, the engagement of spring-biased balls <NUM> and <NUM> with recesses <NUM> and <NUM> acts to retain arm <NUM> in the locked position. When arm <NUM> is in the unlocked position, spring-biased ball <NUM> interfaces with recess <NUM> and spring-biased ball <NUM> interfaces with recess <NUM>. In this position, the engagement of spring-biased balls <NUM> and <NUM> with recesses <NUM> and <NUM> acts to retain arm <NUM> in the unlocked position.

To actuate arm <NUM> from the locked position to the unlocked position, a user can exert a force on second end <NUM> of arm <NUM> sufficient to overcome the biasing forces of spring-biased ball <NUM> and of spring-biased ball <NUM>. When sufficient force is exerted on second end <NUM> of arm <NUM>, arm <NUM> moves from the locked position (<FIG>) to the unlocked position until first end <NUM> of arm <NUM> extends from housing <NUM> and second end <NUM> of arm <NUM> no longer extends from housing <NUM>.

Alternatively, exerting sufficient force on cord <NUM> actuates arm <NUM> from the locked position to the unlocked position. As a pulling force is exerted on cord <NUM> relative to housing <NUM>, cord <NUM> exerts a corresponding rotational force on spool <NUM>. When sufficient force is exerted on spool <NUM>, teeth <NUM> of spool <NUM> push tooth <NUM> of arm <NUM> to the left (from the perspective of <FIG>) along linear axis <NUM>. Thus, if sufficient pulling force is exerted on cord <NUM>, arm <NUM> will be actuated from the locked position (<FIG>).

Referring to <FIG>, a lanyard <NUM> is shown according to an exemplary embodiment. Lanyard <NUM> is similar to lanyard <NUM> or lanyard <NUM> with the exception of the differences described.

Lanyard <NUM> includes fixed coupling unit <NUM> coupled to housing <NUM> via flexible coupler <NUM>. In a specific embodiment, flexible coupler <NUM> is formed from a fabric material. Applicant has observed that flexible coupler <NUM>, such as when flexible coupler <NUM> is formed from a fabric material, absorbs some of the shock load during drop events (e.g., when the object coupled to retractable coupling unit <NUM> is dropped), thereby reducing the load on the components within lanyard <NUM> and correspondingly reducing the likelihood of components within lanyard <NUM> being broken and/or damaged.

It should be understood that the figures illustrate the exemplary embodiments in detail, and it should be understood that the present application is not limited to the details or methodology set forth in the description or illustrated in the figures. It should also be understood that the terminology is for description purposes only and should not be regarded as limiting.

Further modifications and alternative embodiments of various aspects of the disclosure will be apparent to those skilled in the art in view of this description. Accordingly, this description is to be construed as illustrative only. The construction and arrangements, shown in the various exemplary embodiments, are illustrative only. Although only a few embodiments have been described in detail in this disclosure, many modifications are possible (e.g., variations in sizes, dimensions, structures, shapes and proportions of the various elements, values of parameters, mounting arrangements, use of materials, colors, orientations, etc.) without materially departing from the novel teachings and advantages of the subject matter described herein. Some elements shown as integrally formed may be constructed of multiple parts or elements, the position of elements may be reversed or otherwise varied, and the nature or number of discrete elements or positions may be altered or varied. The order or sequence of any process, logical algorithm, or method steps may be varied or re-sequenced according to alternative embodiments. Other substitutions, modifications, changes and omissions may also be made in the design, operating conditions and arrangement of the various exemplary embodiments without departing from the scope of the invention, as defined by the appended claims.

Claim 1:
A lanyard (<NUM>, <NUM>, <NUM>) comprising:
a housing (<NUM>, <NUM>) comprising an opening (<NUM>);
a reel (<NUM>, <NUM>) rotatably mounted within the housing (<NUM>, <NUM>);
an elongate structure (<NUM>, <NUM>) wound around the reel (<NUM>, <NUM>), the elongate structure (<NUM>, <NUM>) having an inner end coupled to the reel (<NUM>, <NUM>) and an opposing outer end (<NUM>) extending out of the opening (<NUM>);
a first coupling mechanism coupled (<NUM>) to the outer end (<NUM>) of the elongate structure (<NUM>, <NUM>);
a second coupling mechanism (<NUM>) coupled to the housing (<NUM>, <NUM>);
a retraction system (<NUM>) coupled to the reel (<NUM>, <NUM>), wherein the retraction system (<NUM>) biases the elongate structure (<NUM>, <NUM>) to be rewound onto the reel (<NUM>, <NUM>); and
characterized by:
an arm (<NUM>, <NUM>) coupled to the housing (<NUM>, <NUM>), the arm (<NUM>, <NUM>) comprising a body (<NUM>), a first end (<NUM>, <NUM>) of the body (<NUM>), and an opposing second end (<NUM>, <NUM>) of the body (<NUM>), wherein the arm (<NUM>, <NUM>) actuates between:
a locked position in which the first end (<NUM>, <NUM>) extends out of the housing (<NUM>, <NUM>) and the second end (<NUM>, <NUM>) does not extend out of the housing (<NUM>, <NUM>), the arm (<NUM>, <NUM>) interfacing with the reel (<NUM>, <NUM>) to bias the reel (<NUM>, <NUM>) from rotating when the arm (<NUM>, <NUM>) is in the locked position; and
an unlocked position in which the second end (<NUM>, <NUM>) extends out of the housing (<NUM>, <NUM>) and the first end (<NUM>, <NUM>) does not extend out of the housing (<NUM>, <NUM>), wherein the arm (<NUM>, <NUM>) does not bias the reel (<NUM>, <NUM>) from rotating when the arm (<NUM>, <NUM>) is in the unlocked position.