Patent Document

BACKGROUND OF THE INVENTION 
       [0001]    To protect workers who work at heights or are at risk of falling distances, lifelines interconnecting support structures and safety harnesses donned by workers are commonly used. Examples of lifelines include but are not limited to self-retracting lifelines, lanyards, and other suitable lifelines. If a fall event occurs, the lifeline limits the distance the worker could fall, however, injury to the worker could still occur if, for example, the fall distance before the lifeline becomes taut is significant. Energy absorbers are typically used in conjunction with such fall arrest equipment to provide a more gradual, less abrupt stop, which assists in preventing or reducing injuries because energy absorbers absorb some of the kinetic energy of the falling body. 
         [0002]    Energy absorbers could interfere with the operation of such fall arrest equipment, especially if they are relatively large and/or are in positions where they could easily become tangled with the lifelines, safety harnesses, etc. Therefore, the present invention addresses such problems because it is relatively compact and connects securely to the safety harness to reduce the risk of it interfering with other components of the fall arrest equipment. 
         [0003]    For the reasons stated above and for other reasons stated below, which will become apparent to those skilled in the art upon reading and understanding the present specification, there is a need in the art for an energy absorber assembly and components thereof. 
       BRIEF SUMMARY OF THE INVENTION 
       [0004]    The above-mentioned problems associated with prior devices are addressed by embodiments of the present invention and will be understood by reading and understanding the present specification. The following summary is made by way of example and not by way of limitation. It is merely provided to aid the reader in understanding some of the aspects of the invention. 
         [0005]    In one embodiment, an energy absorber assembly for use with a safety harness comprises a connector, a bracket assembly, a fastener, and an energy absorber. The connector is configured and arranged to operatively connect to the safety harness. The fastener operatively connects the bracket assembly and the connector, and the fastener releases the bracket assembly from the connector when subjected to a predetermined load. The energy absorber operatively connects the bracket assembly and the connector, and the energy absorber includes a first portion and a second portion that separate to absorb shock after the bracket assembly is released from the connector. 
         [0006]    In one embodiment, an energy absorber assembly for use with a safety harness comprises a fastener, a connector, a bracket assembly, and an energy absorber. The connector is configured and arranged to operatively connect to the safety harness. The bracket assembly includes a base and a lifeline connector. The base has a slot forming a tab portion with an aperture and a bar portion. The aperture is configured and arranged to receive the fastener. The bar portion is configured and arranged to be engaged by the energy absorber. The lifeline connector is configured and arranged to engage a lifeline. The fastener operatively connects the bracket assembly and the connector. The fastener releases the bracket assembly from the connector when subjected to a predetermined load. The energy absorber operatively connects the bracket assembly and the connector and includes a first portion and a second portion that separate to absorb shock after the bracket assembly is released from the connector. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0007]    The present invention can be more easily understood, and further advantages and uses thereof can be more readily apparent, when considered in view of the detailed description and the following Figures in which: 
           [0008]      FIG. 1  is a front perspective view of a connector in an open position, the connector being a component of an energy absorber assembly constructed in accordance with the present invention; 
           [0009]      FIG. 2  is an exploded front perspective view of the connector shown in  FIG. 1 ; 
           [0010]      FIG. 3  is a rear view of the connector shown in  FIG. 1  in a closed position; 
           [0011]      FIG. 4  is a front view of the connector shown in  FIG. 1  in a closed position; 
           [0012]      FIG. 5  is a front perspective view of an energy absorber assembly constructed in accordance with the present invention; 
           [0013]      FIG. 6  is an exploded front perspective view of the energy absorber assembly shown in  FIG. 5 ; 
           [0014]      FIG. 7  is a front perspective view of another embodiment energy absorber assembly constructed in accordance with the present invention; 
           [0015]      FIG. 8  is an exploded front perspective view of the energy absorber assembly shown in  FIG. 7 ; 
           [0016]      FIG. 9  is a front perspective view of the energy absorber assembly shown in  FIG. 7  illustrating an energy absorbing position; 
           [0017]      FIG. 10  is a schematic view of an energy absorber component of an energy absorber assembly constructed in accordance with the present invention; 
           [0018]      FIG. 11  is a front view of a bracket assembly component of an energy absorber assembly constructed in accordance with the present invention; 
           [0019]      FIG. 12  is a side view of the bracket assembly shown in  FIG. 11 ; 
           [0020]      FIG. 13  is a bottom view of base of the bracket assembly shown in  FIG. 11 ; 
           [0021]      FIG. 14  is a side view of a swivel portion of the bracket assembly shown in  FIG. 11 ; 
           [0022]      FIG. 15  is a front view of the swivel portion shown in  FIG. 14 ; 
           [0023]      FIG. 16  is a side view of the swivel portion rotated 90 degrees from that shown in  FIG. 14 ; 
           [0024]      FIG. 17  is a front view of a first base of another embodiment bracket assembly component of an energy absorber assembly constructed in accordance with the present invention; 
           [0025]      FIG. 18  is a top view of the first base shown in  FIG. 17 ; 
           [0026]      FIG. 19A  is a front view of a second base used with the first base shown in  FIG. 17 ; 
           [0027]      FIG. 19B  is a side view of the second base shown in  FIG. 19A ; 
           [0028]      FIG. 20  is a front view of a base connector for interconnecting the first base shown in  FIG. 17  and the second base shown in  FIG. 19A ; 
           [0029]      FIG. 21  is a bottom view of the base connector shown in  FIG. 20 ; 
           [0030]      FIG. 22  is a top view of the base connector shown in  FIG. 20 ; 
           [0031]      FIG. 23  is a cross-sectional view of the base connector taken along the lines  23 - 23  in  FIG. 20 ; 
           [0032]      FIG. 24  is a rear view of the base connector shown in  FIG. 20 ; 
           [0033]      FIG. 25  is a side view of a fastener used with the base connector shown in  FIG. 20 ; 
           [0034]      FIG. 26  is a front view of another embodiment energy absorber assembly operatively connected to a safety harness and two self-retracting lifelines; 
           [0035]      FIG. 27  is a rear view of a cover of the energy absorber assembly shown in  FIG. 26 ; 
           [0036]      FIG. 28  is a front view of the cover shown in  FIG. 27 ; 
           [0037]      FIG. 29  is a rear view of the cover shown in  FIG. 27 ; 
           [0038]      FIG. 30  is a front view of an energy absorber of the energy absorber assembly shown in  FIG. 26 ; 
           [0039]      FIG. 31  is a front view of the energy absorber shown in  FIG. 30  with an intermediate portion partially unfolded; 
           [0040]      FIG. 32  is a front view of the energy absorber shown in  FIG. 30  with the intermediate portion substantially unfolded; 
           [0041]      FIG. 33  is a front view of a bracket assembly of the energy absorber assembly shown in  FIG. 26 ; 
           [0042]      FIG. 34  is a front view of the bracket assembly shown in  FIG. 33 ; 
           [0043]      FIG. 35  is a bottom view of first and second bases of the bracket assembly shown in  FIG. 33 ; 
           [0044]      FIG. 36  is a bottom view of a connector of the energy absorber assembly shown in  FIG. 26 ; and 
           [0045]      FIG. 37  is a side view of the energy absorber assembly with the cover removed to show how the energy absorber is connected to the connector and the bracket assembly. 
       
    
    
       [0046]    In accordance with common practice, the various described features are not drawn to scale but are drawn to emphasize specific features relevant to the present invention. Reference characters denote like elements throughout the Figures and the text. 
       DETAILED DESCRIPTION OF THE INVENTION 
       [0047]    In the following detailed description, reference is made to the accompanying drawings, which form a part hereof, and in which is shown by way of illustration embodiments in which the inventions may be practiced. These embodiments are described in sufficient detail to enable those skilled in the art to practice the invention, and it is to be understood that other embodiments may be utilized and mechanical changes may be made without departing from the spirit and scope of the present invention. The following detailed description is, therefore, not to be taken in a limiting sense, and the scope of the present invention is defined only by the claims and equivalents thereof. 
         [0048]    Embodiments of the present invention provide for an energy absorber assembly and components thereof. 
         [0049]    One embodiment energy absorber assembly  100  includes a connector  101 , a bracket assembly  120 , an energy absorber  170 , and a cover  190 . Although shown with a self-retracting lifeline  135  operatively connected to the bracket assembly  120 , it is recognized that any suitable type of lifeline could be used and operatively connected to the bracket assembly  120  with or without modifications to the bracket assembly. 
         [0050]    The connector  101  is configured and arranged to operatively connect a safety harness, preferably proximate its dorsal D-ring as is well known in the art, the energy absorber  170 , and the self-retracting lifeline  135  via the bracket assembly  120 . Generally, as shown in at least  FIGS. 1-4 , the connector  101  includes a base  102 , which is generally U-shaped with a first end  103 , a second end  105 , and an intermediate portion  109  interconnecting the ends  103  and  105 . The ends  103  and  105  define an opening  107  therebetween. The first end  103  includes a first locking assembly  104  and the second end  105  includes a second locking assembly  106  configured and arranged to selectively engage a gate  108 . The gate  108  extends through bores in the ends  103  and  105  and spans the opening  107  in a locked position, in which the locking assemblies  104  and  106  prevent the gate  108  from moving. In an unlocked position, in which the locking assemblies  104  and  106  are compressed, the gate  108  slides out of the bore in end  105  to allow access to the opening  107 . The connector  101  is similar to that disclosed in U.S. patent application Ser. No. 13/660,532, which is hereby incorporated by reference in its entirety. This aspect of the connector  101  is described in detail in U.S. patent application Ser. No. 13/660,532. 
         [0051]    The intermediate portion  109 , which differs from the connector disclosed in U.S. patent application Ser. No. 13/660,532, includes a slot  110  forming a first bar portion  111  proximate the opening  107  and a second bar portion  112  opposite the ends  103  and  105 . The first bar portion  111  includes a recessed portion  111   a  on a side proximate the ends  103  and  105 , and the second bar portion  112  includes an aperture  113  proximate its center. A first protrusion  114  extends outwardly at approximately a right angle proximate the second bar portion  112  and the first side  103 , and a second protrusion  115  extends outwardly at approximately a right angle proximate the second bar portion  112  and the second side  105 . 
         [0052]    In this embodiment, a bracket assembly  120  is used. As shown in at least  FIGS. 5 and 6 , the bracket assembly  120  includes a circular base  121  with a crescent shaped slot  122  proximate its bottom that forms a bar portion  121  a proximate the bottom of the slot  122  and a tab portion  123  proximate the top of the slot  122 . The tab portion  123  extends downward relative to the base  121  and includes an aperture  124 . One side of the base  121  includes a swivel connector portion  125 . The swivel connector portion  125  includes a stationary portion  126 , a swivel portion  127 , and a fastener  129  interconnecting the portions  126  and  127 . The stationary portion  126  includes an extension arm  126   a,  which extends outward in a U-shaped manner from proximate the top of the base  121 , and a flange  126   b,  which extends laterally outward from the extension arm  126   a  proximate the center top of the base  121  and includes and aperture  126   c . This is shown in at least  FIGS. 11-13 . The swivel portion  127  includes a tab portion  127   a  and a two prong portion  127   b,  which includes two legs extending outward from the tab portion  127   a  at a distance from one another to form an opening  127   c  therebetween. The tab portion  127   a  includes an aperture  128  and the legs of the two prong portion  127   b  include aligning apertures  130 . The opening  127   c  is configured and arranged to receive the flange  126   b  and the apertures  126   c  and  130  align. The base  121 , including the stationary portion  126 , and the swivel portion  127  are preferably made of alloy steel. The fastener  129 , which could be a rivet as shown, extends through the apertures  126   c  and  130  to connect the stationary portion  126  and the swivel portion  127  in a manner that allows the swivel portion  127  to swivel or pivot relative to the stationary portion  126 . The other side of the base  121 , opposite the swivel portion  127 , includes a shoulder portion  131  extending outward therefrom. A fastener  168 , such as a rivet as shown, extends through the aperture  124  of the bracket assembly  120  and the aperture  113  of the connector  101 . The bracket assembly  120  is pivotable about the fastener  168  relative to the connector  101 , and the swivel connector portion  125  and the shoulder portion  131  contact the respective protrusions  114  and  115 , which act likes stops to limit rotation of the bracket assembly  120 . A lifeline, such as a self-retracting lifeline  135  including a connector portion  136 , is operatively connected to the bracket assembly  120  by a fastener  137  extending through the aperture  128  of the swivel portion  127  and the apertures  136   a  of the connector portion  136 . This bracket assembly  120  provides a universal joint configuration allowing the lifeline to be orientated in many directions with little restriction. 
         [0053]    The energy absorber  170  includes a first portion  171  and a second portion  172  operatively connected by any suitable means well known in the art. One example of how the portions  171  and  172  could be connected is described in U.S. patent application Ser. No. 13/656,119 filed Oct. 19, 2012 and U.S. patent application Ser. No. 13/463,986 filed May 4, 2012, which are hereby incorporated by reference in their entirety. The energy absorber  170  is schematically illustrated in an unassembled position in  FIG. 10 . The first portion  171  has a first end  171   a  and a second end  171   b,  and the second portion  172  has a first end  172   a  and a second end  172   b.  The portions  171  and  172  are operatively connected proximate an intermediate portion  177  of the energy absorber  170 . The first ends  171   a  and  172   a  are positioned proximate one another and the second ends  171   b  and  172   b  are positioned proximate one another. 
         [0054]    To connect the energy absorber  170  to the connector  101 , one of the first end  171   a  of the first portion  171  and the second end  172   b  of the second portion  172  is positioned proximate the recessed portion  111   a  of the first bar portion  111 , the other of the first end  171   a  of the first portion  171  and the second end  172   b  of the second portion  172  is positioned proximate the slot  110 , and the ends  171   a  and  172   b  are operatively connected, such as by stitching, as a first connection  173  to form a first loop  174  about the first bar portion  111 . 
         [0055]    To connect the energy absorber  170  to the bracket assembly  120 , one of the second end  171   b  of the first portion  171  and the first end  172   a  of the second portion  172  is inserted through the slot  122  from one side of the base  121 , the other of the second end  171   b  of the first portion  171  and the first end  172   a  of the second portion  172  is positioned proximate the other side of the base  121 , and the ends  171   b  and  172   a  are operatively connected, such as by stitching, as a second connection  175  to form a second loop  176  about the bar portion  121   a  of the base  121 . 
         [0056]    After the energy absorber  170  is connected to the other components, it is folded to form an upside down V-shape, which corresponds to the shape of the shoulder straps of the safety harness. The energy absorber  170  includes a first side  179 , a second side  180 , and a bottom portion  178 , which interconnects the sides  179  and  180 . It does not matter on which sides of the safety harness the sides  179  and  180  of the energy absorber  170  are positioned. Generally, as shown in  FIGS. 30-32 , each side of the energy absorber  170  is folded three times so that each segment between folds is approximately the same length. The first side  179  includes a first fold  179   a,  a second fold  179   b,  and a third fold  179   c.  The second side  180  includes a first fold  180   a,  a second fold  180   b,  and a third fold  180   c.  The bottom portion  178  is positioned proximate the connections  173  and  175 , which form the point of the “V”. Once positioned in a folded configuration, a cover  190  can be positioned about the energy absorber  170  to assist in keeping it in its folded configuration. 
         [0057]    As shown in at least  FIGS. 26-29 , the cover  190  is generally a sleeve having an upside down V-shaped configuration corresponding to the energy absorber  170  in its folded configuration. The cover  190  includes a top portion  191 , a first leg  192   a,  and a second leg  192   b . Proximate the bottom, the first leg  192   a  includes a first strap  193   a  with a first end  194   a,  a second end  196   a,  and a first fastener assembly  197   a,  which is configured and arranged to releasably connect the ends  194   a  and  196   a.  Proximate the bottom, the second leg  192   b  includes a second strap  193   b  with a first end  194   b,  a second end  196   b,  and a second fastener assembly  197   b,  which is configured and arranged to releasably connect the ends  194   b  and  196   b.  As shown, each of the fastener assemblies  197   a  and  197   b  includes mating hook and loop but it is recognized that other suitable fastener assemblies could be used to connect the respective ends. 
         [0058]    The front side  198  of the cover  190  is shown in  FIG. 28 . A flap portion  199  extends upward from the top portion  191  and includes a first portion  200  of a fastener, for example one of mating hook and loop. The rear side  201  of the cover  190  is shown in  FIG. 29 . The top portion  191  includes an opening  203  between the front side  198  and the rear side  201 , which form a cavity  204  therebetween. The rear side  201  includes a second portion  202  of the fastener, for example, the other of mating hook and loop. 
         [0059]    To put the cover  190  on the energy absorber  170 , the first side  179  is inserted through the opening  203  and in the cavity  204  proximate the first leg  192   a  and the second side  180  is inserted through the opening and in the cavity  204  proximate the second leg  192   b.  The sides  179  and  180  may be positioned in the cavity  204  in any order and even substantially simultaneously. Then, the top portion  191  is inserted through the slot  110  of the connector  101 , as shown in  FIG. 27 , so that it can be inserted through the opening  204  and the fasteners  200  and  202  mate. The straps  193   a  and  193   b  are wrapped around the shoulder straps of the safety harness and the ends of the respective straps are connected as shown in  FIG. 26 . 
         [0060]    Should a fall occur, the fastener  168  deforms or breaks so that the bracket assembly  120  disconnects from the connector  101 , the top portion  191  of the cover  190  disconnects from the rear side  201 , and the portions  171  and  172  of the energy absorber  170  begin to separate and come out of the cover  190  thereby reducing the rate of fall and the amount of force exerted on the user from the fall. Depending upon the distance of the fall, varying lengths of the portions  171  and  172  could separate. 
         [0061]    Another embodiment energy absorber assembly  100 ′ is similar to the energy absorber assembly  100  except that it includes a bracket assembly  140  for connecting two self-retracting lifelines  135  to the connector  101 . Because the energy absorber assembly  100 ′ is similar to the energy absorber assembly  100 , only significant differences will be described in detail. 
         [0062]    As shown in at least  FIGS. 7-9 , the bracket assembly  140  includes a first circular base  141  configured and arranged to operatively connect to a first self-retracting lifeline  135  and a second circular base  151  configured and arranged to operatively connect to a second self-retracting lifeline  135 . 
         [0063]    The first circular base  141 , shown in at least  FIGS. 17 and 18 , is generally ring-like and includes an aperture  142 . A first side  143  of the base  141  includes a protrusion  144  extending outward proximate the top, and a second side  145  of the base  141  includes a first swivel connector portion  146  extending outward proximate the top. The first swivel connector portion  146  includes a stationary portion  147 , which includes an extension arm  147   a  and a flange  147   b  having an aperture  147   c.  Rather than extending inward in a U-shaped manner like the stationary portion  126  of the bracket assembly  120 , the stationary portion  147  extends outward as shown in  FIG. 18 . A swivel portion  148  is operatively connected to the flange  147   b  similarly as the swivel portion  127  is operatively connected to the flange  126   b.  The swivel portion  148  includes an aperture  149  for connecting a self-retracting lifeline  135  thereto as is well known in the art. 
         [0064]    The second circular base  151 , shown in at least  FIGS. 19A and 19B , is generally a mirror image of the first circular base  141 . The second circular base  151  is generally ring-like and includes an aperture  152 . A first side  153  of the base  151  includes a second swivel connector portion  154  extending outward proximate the top, and a second side  158  of the base  151  includes a protrusion  159  extending outward proximate the top. The second swivel connector portion  154  includes a stationary portion  155  and a swivel portion  156 , which are similar to those of the first swivel connector portion  146 . The swivel portion  156  includes an aperture  157  for connecting a self-retracting lifeline  135  thereto as is well known in the art. 
         [0065]    A base connector  161 , shown in at least  FIGS. 20-24 , is configured and arranged to operatively connect the circular bases  141  and  151  to the connector  101 . The base connector  161  is preferably made of nylon. The base connector  161  includes a generally cylindrical portion  162  to which a plate portion  163  is operatively connected proximate one side and a flange portion  165  is operatively connected proximate an opposing side. The plate portion  163  includes an aperture  164  proximate the center of the cylindrical portion  162 . A segment is removed from the cylindrical portion  162  to form a bottom  166 , which includes an extension  166   a  extending outward from the plate portion  163 . An opening  167  is formed by the flange portion  165  and the bottom  166 . 
         [0066]    The circular bases  141  and  151 , which are preferably made of alloy steel, are positioned together with the swivel connector portions  146  and  154  extending outward from opposing sides and the apertures  142  and  152  aligning. The base connector  161  is inserted through the apertures  142  and  152  so that the ring portions are proximate the cylindrical portion  162 . A fastener  168  extends through the aperture  164  and the aperture  113  to connect the base connector  161  to the connector  101 . The extension  166   a  of the base connector  161  is positioned below the second bar portion  112  of the connector  101  to prevent the base connector  161  from pivoting relative to the connector  101 . Therefore, the circular bases  141  and  151  are positioned between the connector  101  and the flange portion  165 . The circular bases  141  and  151  pivot independently relative to the connector  101  and the base connector  161 , and the swivel connector portions  146  and  154  and the protrusions (shoulder portions)  144  and  159  contact the respective protrusions  114  and  115 , which act likes stops to limit rotation of the circular bases  141  and  151 . 
         [0067]    Similar to the bracket assembly  120 , the energy absorber  170  is connected to the bracket assembly  140  by inserting one of the second end  171   b  of the first portion  171  and the first end  172   a  of the second portion  172  through the apertures  142  and  152  from one side of the circular bases  141  and  151 , the other of the second end  171   b  of the first portion  171  and the first end  172   a  of the second portion  172  is positioned proximate the other side of the circular bases  141  and  151 , and the ends  171   b  and  172   a  are operatively connected, such as by stitching, as a second connection  175  to form a second loop  176  about the ring portions of the bases  141  and  151 . The energy absorber  170  may be connected to the bracket assembly  140  before the base connector  161  is inserted through the apertures  142  and  152  or after the base connector is inserted through the apertures  142  and  152  and connected to the connector  101 . 
         [0068]    Should a fall occur, the fastener  168  deforms or breaks so that the base connector  161  disconnects from the connector  101  thereby releasing the circular bases  141  and  151  from the connector, the top portion  191  of the cover  190  disconnects from the rear side  201 , and the portions  171  and  172  of the energy absorber  170  begin to separate and come out of the cover  190  thereby reducing the rate of fall and the amount of force exerted on the user from the fall. Depending upon the distance of the fall, varying lengths of the portions  171  and  172  could separate. 
         [0069]      FIG. 9  illustrates how the circular bases  141  and  151  may be positioned during a fall. The connector  101  is operatively connected to the user&#39;s safety harness, and the first self-retracting lifeline  135   a  is operatively connected to a support structure. As the portions  171  and  172  of the energy absorber  170  separate, the second self-retracting lifeline  135   b  simply slides along a portion of the energy absorber  170  as the portions  171  and  172  continue to separate. If the second self-retracting lifeline  135   b  were connected to a support structure, the first self-retracting lifeline would similarly slide along a portion of the energy absorber  170  as the portions  171  and  172  separate. 
         [0070]    The above specification, examples, and data provide a complete description of the manufacture and use of the composition of embodiments of the invention. Although specific embodiments have been illustrated and described herein, it will be appreciated by those of ordinary skill in the art that any arrangement, which is calculated to achieve the same purpose, may be substituted for the specific embodiment shown. This application is intended to cover any adaptations or variations of the invention. Therefore, it is manifestly intended that this invention be limited only by the claims and the equivalents thereof.

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