Coupler for a fall protection device

Abstract

A coupler to couple a D-ring from a harness to a fall arrest device connector provides walls to guide and contain the harness webbing whilst allowing it to move freely (reducing webbing wear) and does not necessitate the removal of the coupler, connector, or D-ring as may be required for harness size adjustment. The coupler has a circular passageway which runs through the length allowing a shaft of the connector to couple to the part whilst maintaining 180 degrees of swivel. The coupler also has a groove which runs along the length to fit onto a central bar of the harness D-ring. The design is such that, during a fall, should the device break, the webbing will remain securely coupled to the D-ring of the harness.

Claims

1. A coupler assembly for a fall protection device, comprising: a D-ring; a connector having a shaft; a body having a distal end and a proximal end; the distal end comprising a webbing guidance surface configured and arranged to support webbing; and the proximal end comprising an engagement portion configured and arranged to directly engage the D-ring, the engagement portion comprising first and second elongated portions forming a groove therebetween, the groove configured to receive a portion of the D-ring; the body further comprising a securement passageway positioned between the webbing guidance surface and the engagement portion configured and arranged to receive the shaft of the connector, the securement passageway comprising a bearing surface configured and arranged to enable the shaft of the connector to rotate within the securement passageway and to enable the connector to articulate relative to the body; the D-ring engaging the proximal end of the body and the shaft routed through the securement passageway when assembled, such that the body is configured to route webbing from the proximal end of the body to and around the webbing guidance surface of the distal end of the body, the body configured to be retained by the webbing, the D-ring, and the shaft when assembled, such that when the webbing is installed the webbing biases the body toward the D-ring and the webbing is routed around the body and the shaft, such that if the body breaks the webbing remains routed around the shaft and remains operatively connected to the D-ring.

2. A coupler assembly for a fall protection device according to claim 1 in which the body comprises a single piece component and a shape of the body is moulded to provide all individual elements of the body and the body is absent of any moving components.

3. A coupler assembly for a fall protection device according to claim 1 in which the groove comprises a first lateral side wall, a second lateral side wall and a bottom wall and intersections between the lateral side walls and the bottom wall prevent rotation of the part of the D-ring engaged therein.

4. A coupler assembly for a fall protection device according to claim 1 in which the groove is configured and arranged to prevent rotation of the D-ring.

5. A coupler assembly for a fall protection device according to claim 1 in which the groove comprises a linear engagement groove.

6. A coupler assembly for a fall protection device according to claim 1 in which the groove extends along a full lateral length of the body from a first lateral end to a second lateral end.

7. A coupler assembly for a fall protection device according to claim 1 in which the groove is configured to receive the part of the D-ring to orientate the body outwardly and away from the D-ring and for the distal end of the body to locate outward from the part of the D-ring.

8. A coupler assembly for a fall protection device according to claim 1 in which the groove is configured to secure the orientation of the body relative to the D-ring and prevents significant rotational movement of the body about the part of the D-ring engaged within the groove.

9. A coupler assembly for a fall protection device according to claim 1 in which the webbing guidance surface comprises a curved surface and the webbing guidance surface comprises an upper section, an intermediate section and a lower section and wherein the upper section is substantially parallel to the lower section and the intermediate section comprises a substantially hemi-cylindrical surface.

10. A coupler assembly for a fall protection device according to claim 1 in which the guidance surface has a first lateral side providing a first retaining wall and a second lateral side providing a second retaining wall, wherein the first and second retaining walls are arranged to retain the webbing within the guidance surface.

11. A coupler assembly for a fall protection device according to claim 10 in which the first and second retaining walls extend outwardly from the first and second lateral sides of an intermediate section of the webbing guidance surface and the first and second retaining walls are configured to prevent lateral movement of the webbing relative to the guidance surface and wherein the first and second retaining walls are shaped inwardly as the first and second retaining walls extend from the upper section around the intermediate section and the first and second retaining walls are shaped outwardly as the first and second retaining walls extend from the intermediate section to the lower section.

12. A coupler assembly for a fall protection device according to claim 10 in which the first retaining wall and the second retaining wall define the webbing guidance surface therebetween and a lateral extent of the webbing guidance surface varies between an upper section, intermediate section and a lower section and wherein the lateral extent of the webbing guidance surface gradually decreases from the upper section to the intermediate section and then the lateral extent of the webbing guidance surface gradually increases from the intermediate section to the lower section.

13. A coupler assembly for a fall protection device according to claim 12 in which the intermediate section provides a narrow webbing guidance surface relative to the webbing guidance surface in the upper section and/or the lower section.

14. A coupler assembly for a fall protection device according to claim 1 in which the securement passageway provides a cylindrical passageway and the securement passageway provides a uniform internal bearing surface through the entire lateral width of the body and wherein the securement passageway defines a rotational axis about which a shaft contained therein is rotatable.

15. A coupler assembly for a fall protection device, comprising: a D-ring; a connector having a shaft; a body having a distal end and a proximal end; the distal end comprising a webbing guidance surface configured and arranged to support webbing; and the proximal end comprising an engagement portion configured and arranged to engage the D-ring, the engagement portion comprising first and second elongated portions forming a groove therebetween, the groove configured to receive a portion of the D-ring; the body comprising a single piece component and being absent of any moving components; the body further comprising a securement passageway configured and arranged to receive the shaft of the connector, the securement passageway comprising a bearing surface configured and arranged to enable the shaft of the connector to rotate within the securement passageway and to enable the connector to articulate relative to the body; the D-ring engaging the proximal end of the body and the shaft routed through the securement passageway when assembled, such that the body is configured to route webbing from the proximal end of the body to and around the webbing guidance surface of the distal end of the body, the body configured to be retained by the webbing, the D-ring, and the shaft when assembled, such that when the webbing is installed the webbing biases the body toward the D-ring and the webbing is routed around the body and the shaft, such that if the body breaks the webbing remains routed around the shaft and remains operatively connected to the D-ring.

16. A coupler assembly for a fall protection device according to claim 15 in which the groove comprises a first lateral side wall, a second lateral side wall, and a bottom wall and intersections between the lateral side walls and the bottom wall prevent rotation of the part of the D-ring engaged therein.

17. A coupler assembly for a fall protection device according to claim 16 in which the groove extends along a full lateral length of the body from a first lateral end to a second lateral end.

18. A coupler assembly for a fall protection device according to claim 16 in which the groove is configured to secure the orientation of the body relative to the D-ring and prevents significant rotational movement of the body about the part of the D-ring engaged within the groove.

19. A coupler assembly for a fall protection device according to claim 15 in which the webbing guidance surface comprises a curved surface and the webbing guidance surface comprises an upper section, an intermediate section, and a lower section, and wherein the upper section is substantially parallel to the lower section and the intermediate section comprises a substantially hemi-cylindrical surface.

20. A coupler assembly for a fall protection device according to claim 15 in which the guidance surface has a first lateral side providing a first retaining wall and a second lateral side providing a second retaining wall, wherein the first and second retaining walls are arranged to retain the webbing within the guidance surface.

21. A coupler assembly for a fall protection device according to claim 20 in which the first and second retaining walls extend around an intermediate section of the webbing guidance surface and the first and second retaining walls provide a smooth surfaces to guide the webbing and wherein the first and second retaining walls are shaped inwardly as the first and second retaining walls extend from an upper section around the intermediate section and the first and second retaining walls are shaped outwardly as the first and second retaining walls extend from the intermediate section to a lower section.

22. A coupler assembly for a fall protection device according to claim 20 in which the first retaining wall and the second retaining wall define the webbing guidance surface therebetween and a lateral extent of the webbing guidance surface varies between an upper section, intermediate section and a lower section and wherein the lateral extent of the webbing guidance surface gradually decreases from the upper section to the intermediate section and then the lateral extent of the webbing guidance surface gradually increases from the intermediate section to the lower section.

23. A coupler assembly for a fall protection device according to claim 22 in which the intermediate section provides a narrow webbing guidance surface relative to the webbing guidance surface in the upper section and/or the lower section.

24. A coupler assembly for a fall protection device, comprising: a D-ring; a connector having a shaft; a body having a webbing end and a D-ring end; the webbing end comprising a webbing guidance surface configured and arranged to support webbing; and the D-ring end comprising an engagement portion configured and arranged to directly engage the D-ring, the engagement portion comprising first and second elongated portions forming a groove therebetween, the groove configured to receive a portion of the D-ring; the webbing end of the body further comprising a securement passageway positioned between the webbing guidance surface and the engagement portion configured and arranged to receive the shaft of the connector, the securement passageway comprising a bearing surface configured and arranged to enable the shaft of the connector to rotate within the securement passageway and to enable the connector to articulate relative to the body, the D-ring engaging the D-ring end of the body and the shaft routed through the securement passageway when assembled, such that the body is configured to route webbing from the D-ring end of the body to and around the webbing guidance surface of the webbing end of the body, the body configured to be retained by the webbing, the D-ring, and the shaft when assembled, such that when the webbing is installed the webbing biases the body toward the D-ring and the webbing is routed around the body and the shaft, such that if the body breaks the webbing remains routed around the shaft and remains operatively connected to the D-ring.

25. The coupler assembly for a fall protection device of claim 24, further comprising a fall arrestor coupled to the connector, the fall arrestor operable to slow the rate of fall of a fall protection device user.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) The present invention will now be described, by way of example embodiments, with reference to the drawings that follow, in which:

(2) FIG. 1 is a view of a preferred embodiment of a coupler being used in the connection of a fall protection device to a harness;

(3) FIG. 2 is a perspective view of a preferred embodiment of a coupler engaged with a D-ring and webbing straps of a harness;

(4) FIG. 3 is a perspective view of a preferred embodiment of a coupler and a D-ring of a harness;

(5) FIG. 4 is a perspective view of an embodiment of a D-ring;

(6) FIG. 5 is a perspective view of a preferred embodiment of a coupler;

(7) FIG. 6 is a front view of a preferred embodiment of a coupler;

(8) FIG. 7 is another front view of a preferred embodiment of a coupler;

(9) FIG. 8 is a top view of a preferred embodiment of a coupler;

(10) FIG. 9 is a detailed view of a front view of a preferred embodiment of a coupler as indicated by A in FIG. 6;

(11) FIG. 10 is a cross section through B-B in FIG. 6 of a preferred embodiment of a coupler;

(12) FIG. 11 is a side view of a preferred embodiment of a coupler; and

(13) FIG. 12 is a top view of an embodiment of a coupler.

DESCRIPTION OF EMBODIMENTS

(14) Embodiments of the present invention relate to a coupler 10 for use in the connection of a fall protection device to a harness. The term fall protection device is defined to include both fall restraint devices, fall arrest devices and similar apparatus such as rescue devices. For example, the fall protection device may comprise a self-retracting lanyard (SRL) or self-retracting lifeline or other system. As mentioned above, a fall protection device such as an SRL is arranged to stop and/or absorb some of the energy of a fall by providing a braking system which aims to provide a relatively gradual decrease in the falling speed of a person in order to arrest and stop the fall whilst also not causing injury to the user. Each embodiment of the present invention is of particular use with one or more, preferably two, fall protection devices in which such devices are used to protect a user.

(15) As shown in FIG. 1, FIG. 2, FIG. 3 and FIG. 4, the coupler 10 is arranged to locate between the webbing straps 40 of a harness and a part of a D-ring 30 provided on the harness worn by a user. FIG. 1 shows the coupler 10 in an installed position with the webbing straps 40 extending over and around the coupler 10.

(16) The coupler 10 provides a securement passageway 11 though which a part of a connector 50 can extend in order to secure the connector 50 to the harness. In particular, a shaft 54 of the connector 50 is arranged to extend through the passageway 11. The or each fall protection device 60, 62 includes a fastener or a securement component which may be in the form of a swivel eye 61, 63. The swivel eye(s) 61, 63 may be engaged on a retaining/closed section 52 of the connector 50 and the shaft 54 of the connector 50 is then inserted through the passageway 11 which thereby mounts the fall protection device(s) 60, 62 to the harness.

(17) The connector 50 includes a shaft 54 which is arranged to extend through the securement passageway 11 of the coupler 10. The dimensions of the shaft 54 and the passageway 11 are arranged such that the connector 50 is free to pivot and rotate around the coupler 10. In particular, the longitudinal axis 27 of the passageway 11 defines and provides the rotational/pivotal axis 27 about which the connector 10 is free to pivot/rotate.

(18) In use, the person wearing the harness may be continually moving and the orientation and angle of the fall protection device(s) 60, 62 and associated connector 50 will thereby be wanting to move relative to the person and the harness since the respective lifeline(s) will be tethered at the distal end. In a prior art arrangement, a shaft of the connector may be simply inserted underneath the webbing straps 40 and the D-ring 30 and this may allow movement of the connector 50 relative to the harness. This movement would not be restrained about a fixed rotational axis 27 and the connector 50 may also freely move laterally and/or up and down relative to the webbing straps 40 under which the connector shaft 54 is restrained. The continual movement (rotational, lateral and other translational movement) of the connector 50 against the webbing will gradually cause wear and tear of the webbing 40 and may therefore weaken the webbing 40. Accordingly, such a harness may become hazardous and dangerous due to this weakness being introduced through the use of the harness. Embodiments of the present invention prevent such wear and tear on the webbing since the connector 50 freely rotates within the passageway provided by the coupler. Any significant relative up/down forces are accommodated through pivoting/rotation. In addition, relative lateral movement is restrained by the capture of the webbing 40 by lateral guide walls 17, 19 and the shaft 54 may be a permitted to have a restricted amount of lateral movement through the passageway 11.

(19) In addition, the coupler 10 allows the webbing straps 40 to be moved (lengthened/shortened) such as required through the adjustment of the harness as required by a user.

(20) The coupler 10 can simply be inserted by pulling the webbing straps 40 away from the D-ring 30. The coupler 10 can then be inserted and the webbing straps 40 tightened/pulled back through the D-ring pad 70 to secure the coupler 10 in position. Such a simple and easy installation method enables the coupler 10 to be easily installed and/or replaced should this be needed, for example if damage is noted or if weakening is suspected.

(21) An embodiment of the coupler 10 will now be described in more detail with reference to a system incorporating two fall protection devices 60, 62.

(22) As shown in FIGS. 5 to 12, the coupler 10 comprises a single component. In particular, the coupler is a single moulded body and preferably comprises nylon. However, other suitable materials may be used.

(23) The coupler 10 comprises a first surface or top/distal end 12 and a second surface or bottom/proximal end 14. The coupler has a first lateral end 16 and a second (opposite) lateral end 18.

(24) The top/distal end 12 provides a shaped surface over which the webbing straps 40 are arranged to locate, in use. The shaped surface provides a smooth curved surface over which the webbing straps 40 can be safely retained.

(25) The lateral ends 16, 18 of the coupler provide a respective guide/retaining wall 17, 19 to maintain the webbing straps 40 extending over the distal end 12 and the shaped surface of the coupler 10. The retaining walls 17, 19 prevent the lateral movement of the coupler 10 in to a position out of alignment with the webbing straps 40. Such a position may cause the webbing straps 40 to be worn away though movement whilst located at a position of the intersection between the shaft 54 and the retaining section 52 of the connector 50. Such an intersection may be angled and may readily cause excessive abrasion of the webbing 40 through repeated movement.

(26) The proximal end 14 of the coupler 10 provides an engagement portion 14a to engage the D-ring 30 and to secure the coupler 10 relative to the D-ring 30. In the preferred embodiment, a groove 15 or channel is defined along the proximal end 14 into which a part of the D-ring 30 is arranged to be engaged. The groove 15 extends along the full width of the coupler 10. The groove 15 is arranged to engage with a reinforcement member or brace 32 of the D-ring 30. In particular, the groove is arranged to engage an intermediate brace 23 provided by the D-ring 30.

(27) The D-ring provides a closed loop or ring 38 by which a single conventional fall protection device may be connected. However, such a ring 38 or loop could cause problems if two independent fall protection devices are to be secured to the harness. For this reason, connectors are commonly used for dual/double fall protection device systems and similar connectors may also be used for single fall protection device systems.

(28) As shown in FIG. 4, the D-ring 30 includes a lower brace/reinforcement member 34, an upper brace/reinforcement member 36 and an intermediate brace/reinforcement member 32. The webbing 40 is arranged to be threaded and criss-crossed through the openings defined between the braces 32, 34, 36. The webbing 40 extends from behind the D-ring 30 and through the opening defined between the upper brace member 36 and the intermediate brace member 32. The webbing 40 then extends back through the opening defined between the intermediate brace member 32 and the lower brace member 34. The coupler 10 is designed to extend away from the intermediate brace member 32 and locates within a space created between the webbing 40 and the front of the D-ring 30, specifically the intermediate brace member 32.

(29) In use, the natural/operational tension within the webbing straps 40 urges the coupler 10 towards the intermediate brace member 32. In particular, the force within the webbing straps 40 is transferred to the shaped surface around the distal end 12 of the coupler 10 which urges the coupler 10 into engagement with the intermediate brace member 32. The tension is maintained within the straps 40 to continually force the coupler into engagement with the D-ring 30. For example, the tension in the straps 40 may be confined by limiters which set the length of the straps and/or the arrangement and path of the straps 40 through the D-ring pad 70 and around the coupler 10.

(30) The retaining groove 15 or channel provided on the proximal end of the coupler 10 allows the simple insertion of the intermediate brace member 32. The dimensions of the groove 51 may be defined to engage and accommodate the intermediate brace member 32 without any significant free movement. The groove 15 may therefore be bespoke to the particular D-ring 30 and dictated by the size and shape of a respective brace member of the D-ring 30.

(31) The groove 15 is defined by two side walls 80, 81 and a connecting bottom wall 82 (see FIG. 10). As explained above, the dimensions (and shape) of the groove 15 is designed to accommodate the respective brace member 32 of the D-ring.

(32) The lateral width of the coupler 10 is arrange such that the coupler 10 can locate between two side members 35, 37 of the D-ring 30. In use, a part of the coupler 10 locates within the openings defined between the upper, intermediate and lower brace members 32, 34, 36 add the side members 35, 37 of the D-ring 30. The coupler provides a first elongate portion 21 and a second elongate portion 23 which locate in different openings either side of the intermediate brace member 32.

(33) The outer end faces of the coupler 10 at each lateral end 16, 18 locate adjacent to opposing inner side surfaces of the side members 35, 37 of the D-ring 30. The interaction between the lateral ends 16, 18 and the side members 35, 37 restrain the lateral movement of the coupler 10 relative to the D-ring 30. This prevents any unnecessary relative movement of the fall protection system and helps the smooth movement of the user whilst attached to the fall arrest/protection device (and/or associated lifelines).

(34) The coupler 10 provides a passageway 11 which extends from the first lateral end 16 to the second lateral end 18. A shaft 54 of the connector is arranged to extend through the passageway 11. The inner surface of the passageway 11 provides a bearing surface which surrounds the outer surface of the connector shaft 54. The longitudinal axis 27 of the passageway 11 thereby provides a rotational axis 27 about which the connector 10 is constrained to rotate/pivot without any excessive translational movement.

(35) The rotational movement of the connector shaft 54 within the bearing surface of the passageway 11 thereby prevents direct abrasion of the webbing straps 40 which would otherwise occur.

(36) The connector 50 and/or connector shaft 54 may have abutment surface or collars 56, 57 which restrict the amount of relative longitudinal/axial movement of the coupler along the shaft 54. Again, this further provides predictable restraint to the user without instigating sudden changes in the restraining forces of the fall protection devices as the user moves around. Additionally and importantly, this reduces any wear on the webbing straps 40 which may change the integrity of the fall protection system.

(37) The dimensions of the shaft 54 may be selected so as to closely cooperate with the internal bearing surface of the passageway 11 so as to provide a (integral) plain bearing arrangement. In particular, the shaft 54 will act as the journal and rotate within the confines of the bearing surface provide by the internal cylindrical surface of the passageway 11. The passageway 11 may therefore be bespoke to the particular shaft 54/connector 50 and dictated by the size and shape of the respective shaft 54 (or vice versa). Specifically, the diameters of the passageway 11 and shaft 54 will be bespoke and matched.

(38) Each fall protection device 60, 62 has a fastener in the form of a swivel eye 61, 63 (see FIG. 1). These swivel eyes 61, 63 provide closed loops or rings and enable the respective fall protection device 60, 62 to rotate and these fasteners reduce the resistance to movement as the user moves around. The swivel eyes 61, 63 are mounted on the closed side 52 of the connector 50 which is opposite the shaft 54. The shaft 54 thereby acts as a gate within the connector 50 whilst the closed side provides a retaining section 52. The retaining section 52 and the shaft 54 thereby form a contiguous loop or contiguous ring in the connected configuration and are configurable to provide an open loop/ring to enable the swivel eyes 61, 63 to be mounted on the connector 50. Therefore, the fall protection device 60, 62 rotates about the connector 50 and swivels about the swivel eyes 61, 63 to move in two different directions.

(39) The shaft 54 is movable from an open position to a closed position and may be movable translationally along a longitudinal/axial direction. In the open position, an exposed/distal end of the shaft 54 can be inserted into the passageway 11 and the elongate shaft portion can be subsequently moved into the passageway 11 until the exposed/distal end of the shaft 54 engages with a securement device which enables the connector 50 to be locked in a closed position. The securement device may comprise a typical carabiner style connector in which the release mechanism may require a user to rotate a collar around the axis to enable the shaft to be withdrawn to an open position. The mechanism may have urging means such as a biasing member or a spring arrangement to force the shaft to a normally closed and locked position to prevent the connector 50 being inadvertently left in an unsafe configuration.

(40) In the closed position the webbing straps are positioned within the aperture/opening of the connector 50 albeit the webbing straps are protected by the coupler 10. Accordingly, the coupler 10 facilitates the movement of the fall protection device relative to the webbing straps 40 (and user/harness) which prevents wear and tear/abrasion or other potential damage to the webbing straps 40.

(41) In the event of a fall, even if the coupler 10 was to fracture or even catastrophically fail, then the webbing straps would still be retained within the connector 50.

(42) In summary, embodiments of the present invention provide a connecting device (e.g., coupler 10) to couple a D-ring 30 from a harness to a dual fall arrest device connector 50 (which connects to one or more fall arrest blocks). The coupler 10 is preferably constructed from a single moulded piece of material (for example, nylon). The coupler 10 provides (inner) lips or walls 17, 19 which are curved with a variable fillet which guides and contains the webbing 40 whilst allowing it to move freely (reducing webbing wear) and does not necessitate the removal of either the device (coupler 10), connector 50 or D-ring 30 (as may be required for harness size adjustment). The coupler 10 has a single circular passageway 11 which runs through the length allowing the shaft 54 of a connector 50 to couple to the part whilst maintaining 180 degrees of swivel. The coupler 10 also has a groove 15 which runs along the length to fit onto the central bar 32 of a harness D-ring 30. The design is such that during a fall, should the device break the webbing 40 will remain securely coupled to the D-ring 30 of the harness.