TECHNICAL FIELD
The following disclosure relates generally to personal restraint systems for use in vehicles and, more particularly, to buckle assemblies and associated connectors for use with child seats and other restraint systems.
BACKGROUND
There are many types of personal restraint systems for use in automobiles, aircraft, all-terrain-vehicles, and other vehicles. Such systems include, for example, seat belts for use by adults and children of sufficient size, and child seats with associated restraints for use by toddlers and small children.
One method of securing the seat belts or webs around an occupant includes releasably attaching an end portion of each of the webs to a buckle assembly. The buckle assembly retains the webs around the occupant during use, and also enables the occupant to release or separate the webs after use. Conventional buckle assemblies can be positioned to the side of an occupant or in front of an occupant. For example, a “three point” harness system, as typically found in conventional automobiles, can include a shoulder web and a lap web that are releasably secured to a buckle assembly positioned proximate to the occupant's hip. A “five point” harness system can include a crotch web, first and second shoulder webs, and first and second lap webs that are releasably secured to a buckle assembly positioned proximate to the occupant's mid-section.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an isometric view of a child secured in a child seat with a restraint system having a buckle assembly configured in accordance with an embodiment of the disclosure.
FIGS. 2A and 2B are a series of top views illustrating various operational aspects of the buckle assembly and web connectors shown in FIG. 1.
FIG. 3 is an isometric view of one of the web connectors of FIGS. 1-2B.
FIG. 4 is an exploded isometric view of the buckle assembly of FIGS. 1-2B.
FIGS. 5A and 5B are isometric views of covers of the buckle assembly of FIG. 4.
FIG. 6 is an isometric view of a frame of the buckle assembly of FIG. 4.
FIG. 7 is an isometric view of a locking member of the buckle assembly of FIG. 4.
FIG. 8 is an isometric view of a button of the buckle assembly of FIG. 4.
FIGS. 9A-9H are a series of cross-sectional views taken substantially along the lines 9-9 of FIG. 2B illustrating various operational aspects of the buckle assembly and corresponding components illustrated in FIGS. 1-8.
DETAILED DESCRIPTION
The following disclosure describes buckle assemblies and associated web connectors for use with child seats and other personal restraint systems in vehicles. As described in greater detail below, a personal restraint system configured in accordance with one aspect of the disclosure can include two web connectors with corresponding tongues that are releasably engaged with a corresponding buckle assembly. Certain details are set forth in the following description and in FIGS. 1-9H to provide a thorough understanding of various embodiments of the disclosure. However, other details describing well-known structures and systems often associated with buckle assemblies, web connectors, and/or other aspects of personal restraint systems are not set forth below to avoid unnecessarily obscuring the description of various embodiments of the disclosure.
Many of the details, dimensions, angles, and other features shown in the Figures are merely illustrative of particular embodiments of the disclosure. Accordingly, other embodiments can have other details, dimensions, angles, and features without departing from the spirit or scope of the present disclosure. In addition, those of ordinary skill in the art will appreciate that further embodiments of the disclosure can be practiced without several of the details described below.
In the Figures, identical reference numbers identify identical or at least generally similar elements. To facilitate the discussion of any particular element, the most significant digit or digits of any reference number refers to the Figure in which that element is first introduced. For example, element 110 is first introduced and discussed with reference to FIG. 1.
FIG. 1 is an isometric view illustrating a restraint system 100 having a buckle assembly 110 configured in accordance with an embodiment of the disclosure. In the illustrated embodiment, the restraint system 100 holds a vehicle occupant 10 (e.g., a child) in a child seat 101. In other embodiments, however, the restraint system 100 and associated buckle assembly 110 can restrain other types of occupants in vehicles without a child seat 101. In the illustrated embodiment, the child seat 101 includes a base portion 103 and a back portion 107. The child seat 101 can be secured to a vehicle seat 20 using various systems known in the art. Such systems can include, for example, belts or webs (not shown) having proximal ends attached to the child seat 101 and distal ends attached to anchors (also not shown) in the bight of the vehicle seat 20 with suitable couplings. In other embodiments, the child seat 101 can be secured to the vehicle seat 20, and/or other vehicle structures, using other suitable methods known in the art. Moreover, in further embodiments the child seat 101 or variations thereof can be reversed so that the child seat 101 is facing rearward toward the vehicle seat 20. Accordingly, as the foregoing illustrates, embodiments of the present disclosure and applications of the buckle assemblies and web connectors disclosed herein are not limited to the particular child seat configuration illustrated in FIG. 1.
In the illustrated embodiment, the restraint system 100 includes a first shoulder web 102a and a second shoulder web 102b extending from the back portion 107 of the child seat 101. The shoulder webs 102 can include various types of woven fabric materials and/or other suitable belt or strap materials known in the art that provide sufficient strength, flexibility, durability and/or other characteristics. In this embodiment, each of the shoulder webs 102 slidably passes through an aperture in a corresponding web connector 112 (identified individually as a first web connector 112a and a second web connector 112b). Passing the shoulder webs 102 through the web connectors 112 divides each of the shoulder webs 102 into a corresponding shoulder web portion 106 (identified individually as a first shoulder web portion 106a and a second shoulder web portion 106b), and a corresponding lap web portion 104 (identified individually as a first lap web portion 104a and a second lap web portion 104b). The lap web portions 104 extend away from each other toward opposite sides of the child seat 101. The end portions of the shoulder webs 102 can be secured or otherwise affixed to the child seat 101 and/or other adjacent structures using various methods known in the art.
As described in greater detail below, the web connectors 112 can be releasably coupled to the buckle assembly 110. In the illustrated embodiment, the buckle assembly 110 is attached to a distal end of a crotch web 105 that extends from the base portion 103 of the child seat 101. The proximal end of the crotch web 105 can be secured to the child seat 101 and/or other adjacent structures using various methods known in the art. Although FIG. 1 illustrates one possible use of the buckle assembly 110 (e.g., use with a “five point” harness), those of ordinary skill in the art will appreciate that the buckle assembly 110 and the other components of the restraint system 100 can be used in a number of other restraint system applications without departing from the spirit or scope of the present disclosure.
FIGS. 2A and 2B are a series of top views illustrating various operational aspects of the buckle assembly 100 and web connectors 112 shown in FIG. 1. Referring first to FIG. 2A, each of the web connectors 112 includes a tongue 214 (identified individually as a first tongue 214a and a second tongue 214b) and a web receiving portion 216 (identified individually as a first web receiving portion 216a and a second web receiving portion 216b). Each tongue 214 includes a locking feature or pawl aperture 217 (identified individually as a first pawl aperture 217a and a second pawl aperture 217b) having an engagement portion or edge 219 (identified individually as a first engagement edge 219a and a second engagement edge 219b). Each of the web receiving portions 216 slidably receives one of the corresponding shoulder webs 102.
In another aspect of this embodiment, the buckle assembly 110 includes a release actuator or button 220 at least partially positioned within a housing 222. The buckle assembly 110 also includes a web receiving portion 221 that slidably receives the crotch web 105. To releasably engage the web connectors 112 with the buckle assembly 110, a user can push the tongues 214 into the buckle assembly 110 until they fully engage the buckle assembly 110 as illustrated in FIG. 2B (e.g., until the engagement edge 219 of each tongue 214 engages corresponding locking features of the buckle assembly 110). Further details and associated operational aspects of the buckle assembly 110 are described below with reference to FIGS. 3-9H.
FIG. 3 is an isometric view of the first web connector 112a of FIGS. 1-2B. As will be appreciated by one of ordinary skill in the art, the features described with reference to the first web connector 112a of FIG. 3 are also included in the second web connector 112b. In the illustrated embodiment, the first web connector 112a includes a connector body 324 comprising the tongue 214 and the web receiving portion 216. In certain embodiments, the connector body 324 can be formed from metal, such as plate steel that is stamped or otherwise formed using suitable methods. In other embodiments, however, the connector body 324 can be made from other suitable metals or other materials. As noted above, the tongue 214 includes the engagement edge 219 of the pawl aperture 217. The connector body 324 also includes a web aperture 326 in the web receiving portion 216 to slidably receive the corresponding shoulder web 102 (FIGS. 1-2B).
In another aspect of this embodiment, the first web connector 112a includes a durable cover 328 that fits over the web receiving portion 216 of the connector body 324 to facilitate grasping and manipulation of the first web connector 112a by a user. The cover 328 has an inner edge portion 327 that provides a complimentary fit with a corresponding inner edge portion of the second web connector 112b when the connectors 112 are inserted into the buckle assembly 110 (FIG. 2B). The cover 328 also has an outer edge portion 329 that generally corresponds to the shape of the housing 222 of the buckle assembly 110 when the first web connector 112a is fully inserted into the buckle assembly 110. In certain embodiments, the cover 328 can be formed from textured plastic and/or other suitable materials that are bonded, press fit, and/or otherwise attached to the connector body 324. In one embodiment, for example, the cover 328 can be formed from a tactile material, such as the material disclosed in U.S. Provisional Patent Application No. 61/258,110, entitled “COATINGS FOR BUCKLE ASSEMBLY COMPONENTS AND ASSOCIATED METHODS OF USE AND MANUFACTURE” and filed Nov. 4, 2009, which is incorporated herein in its entirety by reference.
FIG. 4 is an exploded isometric view illustrating various components of the buckle assembly 110. In one aspect of this embodiment, the housing 222 of the buckle assembly 110 includes a first or top cover 423 opposite a second or bottom cover 425. The top cover 423 can include a button aperture 431 and a web opening 432. The bottom cover 425 can include cover locating features 433 (identified individually as a first cover locating feature 433a and a second cover locating feature 433b) projecting upwardly therefrom. The bottom cover 425 also includes a web recess 434 opposite two tongue recesses 415 (identified individually as a first tongue recess 415a and a second tongue recess 415b). The bottom cover 425 further includes biasing member locating features 435 (identified individually as a first biasing member locating feature 435a and a second biasing member locating feature 435b). Further details regarding the top cover 423 and the bottom cover 425 are described below with reference to FIGS. 5A and 5B, respectively.
In another aspect of the embodiment illustrated in FIG. 4, the buckle assembly 110 includes a frame 430 configured to be positioned in the housing 222. The frame 430 includes opposing sidewalls 437 (identified individually as a first sidewall 437a and a second sidewall 437b) extending away from a base 436. Each of the sidewalls 437 includes a guide channel 438. The frame 430 also includes an attachment opening 440 (e.g., a web attachment opening) opposite a tongue receiving portion 442. The tongue receiving portion 442 includes two tongue apertures or openings 443 (identified individually as a first tongue opening 443a and a second tongue opening 443b) that are configured to be aligned with the tongue recesses 415 in the bottom cover 425 to receive the tongues 214 of the corresponding web connectors 112 (FIGS. 2A and 2B). The frame 430 further includes a button opening 444 that receives at least a portion of the button 220 as the button 220 moves in the buckle assembly 110. Further details regarding the frame 430 are described below with reference to FIG. 6.
In yet another aspect of the embodiment illustrated in FIG. 4, the buckle assembly 110 also includes a locking member 450 that is slidably positioned between the frame 430 and the bottom cover 425. The locking member 450 includes a pin opening 452 extending laterally therethrough that is configured to receive a guide member or pin 454 (e.g., an elongate metal pin or rod). The pin 454 has end portions 455 (identified individually as a first end portion 455a opposite a second end portion 455b) that are slidably received in the guide channels 438 of the corresponding sidewalls 437 of the frame 430. The locking member 450 also includes a button contact surface 456 positioned between tongue contact surfaces 458 (identified individually as a first tongue contact surface 458a and a second tongue contact surface 458b). The locking member 450 further includes a base surface 457 that contacts corresponding biasing members or coil springs 460 (identified individually as a first coil spring 460a and a second coil spring 460b). The coils springs 460 are compressed against the corresponding biasing member locating features 435 in the bottom cover 425 and urge the locking member 450 away therefrom. The pin 454, which extends through the locking member 450, slides in the corresponding guide channels 438 to limit the movement of the locking member 450 with reference to the frame 430. Further details regarding the locking member 450 are described below with reference to FIG. 7.
According to a further aspect of the embodiment illustrated in FIG. 4, the button 220 includes pivot legs 463 (identified individually as a first pivot leg 463a opposite a second pivot leg 463b) extending outwardly from the button 220. The pivot legs 463 are positioned between the top cover 423 and the base 436 of the frame 430 to allow the button 220 to pivot within the buckle assembly 110 when a user depresses or otherwise actuates the button 220. Further details regarding the button 220 are described below with reference to FIG. 8, and further details regarding the assembly and operation of the buckle assembly 110 are described below with reference to FIGS. 9A-9H.
FIG. 5A is an isometric view of the top cover 423 of the buckle assembly 110 of FIG. 4. In the illustrated embodiment, the top cover 423 includes locating features 564 (identified individually as a first locating feature 564a and a second locating feature 564b) on opposite sides of the button opening 431. The top cover 423 also includes a proximal end portion 565 opposite a distal end portion 566. The proximal end portion 565 includes the web opening 432, as well as a pivot leg recess 567 extending laterally across the top cover 423. The pivot leg recess 567 is configured to at least partially receive the pivot legs 463 of the button 220. The distal end portion 566 of the top cover 423 includes a rib portion 568 extending between the top cover locating features 564 adjacent to the button aperture 431. The distal end portion 566 also includes frame positioning features or ribs 569 (identified individually as first-fifth frame positioning ribs 569a-569e). In the illustrated embodiment, each of the first frame position rib 569a, the third frame positioning rib 569c, and the fifth frame positioning rib 569e includes a frame contacting portion 563 configured to contact and/or align the tongue receiving portion 442 of the frame 430 with the bottom cover 425 (FIG. 4).
FIG. 5B is an isometric view of the bottom cover 425 of the buckle assembly 110 of FIG. 4. In the illustrated embodiment, the bottom cover 425 includes the bottom cover locating features 433 on opposite sides of a cavity 570. The bottom cover locating features 433 are configured to be aligned with and/or coupled to the corresponding top cover locating features 564 of the top cover 423 (FIG. 5A). The bottom cover 425 also includes frame sidewall guides 576 (identified individually as a first frame sidewall guide 576a and a second frame sidewall guide 576b) extending from the corresponding bottom cover locating features 433 toward the proximal end portion 573. The illustrated embodiment further includes several raised portions 571 extending along the bottom cover 425 in the cavity 570 from the proximal end portion 573 to a distal end portion 572 of the bottom cover 425. The distal end portion 572 includes a divider rib 574 separating the first tongue recess 415a from the second tongue recess 415b. The proximal end portion 573 includes the web recess 434, as well as the biasing member locating features 435 recessed from a rear wall 575 of the bottom cover 425.
In one embodiment, each of the top cover 423 and the bottom cover 425 can be formed from plastics (e.g., ejection-molded plastics), composites, and/or other suitable non-metallic materials known in the art. In other embodiments, however, top cover 423 and/or the bottom cover 425 can be formed from suitable metallic materials, such as cast metals.
FIG. 6 is an isometric view of the frame 430 of the buckle assembly 110 of FIG. 4. In the illustrated embodiment, the sidewalls 437 are configured to be positioned adjacent and interior to the frame sidewall guides 576 in the bottom cover 425 (FIG. 5B). The frame 430 also includes a proximal end portion 677 with the attachment opening 400 opposite a distal end portion 578 with the tongue receiving portion 442 and corresponding tongue openings 443. The frame 430 further includes the button opening 444 extending through the base 436. The button opening 444 has an extension portion 679 extending toward the proximal end portion 677 of the frame 430. As such, the shape of the button opening 444 generally corresponds to the various projections or surfaces extending away from the button 220, which are described in detail below with reference to FIG. 8.
According to another feature of the illustrated embodiment, the frame 430 includes locking features 680 (identified individually as a first locking feature 680a and a second locking feature 680b) extending from the distal end portion 678 toward the proximal end portion 677 and are adjacent to the button opening 444. The locking features are offset from the base 436 and configured to extend toward the bottom cover 425 when the frame 430 is positioned between the bottom cover 425 and the top cover 423. Each locking feature 680 includes a locking surface or edge 681 (identified individually as a first locking edge 681a and a second locking edge 681b) that is configured to contact the engagement edge 219 of the corresponding tongue 214.
According to one aspect of the illustrated embodiment, the locking features 680 and the sidewalls 437 are integrally formed with the base 436. In other embodiments, however, the locking features 680 and/or the sidewalls 437 can be separate components that are attached (e.g., welded) to the base 436. Moreover, the frame 430 can be manufactured from a suitable metallic material, such as steel plate that is stamped and formed to shape. In other embodiments, other metals (e.g., other steels, aluminum, etc.) that are stamped, pressed, cast, forged, machined, and/or otherwise formed to shape using suitable methods known in the art can be used. In further embodiments, the frame 430 can be manufactured from composites and/or other suitable nonmetallic materials having suitable strength, stiffness, and/or other characteristics.
FIG. 7 is an isometric view of the locking member 450 of the buckle assembly 110 of FIG. 4. In the illustrated embodiment, the locking member 450 includes the sliding pin aperture 452 extending laterally therethrough, as well as the button contact surface 456 positioned between the tongue contact surfaces 458. The button contact surface 456 and the tongue contact surfaces 458 are positioned at an inclined angle with reference to a base surface 783 of the locking member 450. Moreover, in the illustrated embodiment the button contact surface 456 is generally curved or convex, and each of the tongue contact surfaces 458 is generally flat or planar. In other embodiments, however, these surfaces can include other suitable shapes. For example, all of these surfaces can be planar, or all of the surfaces can be curved.
According to another aspect of the illustrated embodiment, the base surface 457 of the locking member 450 extends from the base surface 783 toward an upper surface 784. The locking member 450 also includes a tongue locking feature or shelf 785 between the upper surface 784 and each of the button contact surface 456 and the tongue contact surfaces 458. The shelf 785 includes a first tongue engagement surface 786a extending generally perpendicular to a second tongue engagement surface 786b. As explained in detail below, the tongue engagement surfaces 786 engage or otherwise support the tongues 214 when the web connectors 112 are fully inserted into the buckle assembly (FIG. 2B).
In one embodiment, the locking member 450 can be formed from plastics (e.g., ejection-molded plastics), composites, and/or other suitable non-metallic materials known in the art. In other embodiments, however, the locking member 450 can be formed from suitable metallic materials, including, for example, cast metals.
FIG. 8 is an isometric view of the button 220 of the buckle assembly 110 of FIG. 4. In the illustrated embodiment, the pivot legs 463 extend outwardly from a pivot portion 862. The button also includes an ejecting feature 888 projecting from an underside 887 of the button 220. The ejecting feature 888 is spaced apart from the pivot portion 862 and includes a proximal end portion 889 opposite a distal end portion 890. The distal end portion 890 includes a tongue urging surface 891 having a first lateral side portion 892a opposite a second lateral side portion 892b. In the illustrated embodiment, the tongue urging surface 891 is generally planar and generally parallel to the underside 887 of the button 220. The proximal end portion 889 of the ejecting feature 888 includes a locking member urging surface 893. In the illustrated embodiment, the locking member urging surface 893 is generally planar and positioned at an inclined angle with reference to the underside 887 of the button 220. As explained in detail below with reference to FIG. 9A-9H, the ejecting feature 888 is configured to pivot within the housing 222 to move or displace the locking member 450 and the tongues 214 and disengage the corresponding web connectors 112 from the buckle assembly 110. For example, the tongue urging surface 891 is configured to contact and/or slide against the tongues 214, and the locking member urging surface 893 is configured to contact and/or slide along the locking member 450 when a user depresses or otherwise actuates the button 220 to release the web connectors 112 from the buckle assembly 110.
FIGS. 9A-9H are a series of cross-sectional views taken substantially along the lines 9-9 of FIG. 2B illustrating various stages of operation of the buckle assembly 110 and the corresponding components described above with reference to FIGS. 1-8. Referring first to FIG. 9A, the frame 430 is secured in the housing 222 between the top cover 423 and the bottom cover 425. The top cover 423 pivotally retains the button 220 against the frame 430, and the bottom cover 425 slidably retains the locking member 450 against the frame 430. As shown in FIG. 9A, the coil springs 460 urge the locking member 450 toward the tongue 214 in a first or locked position. When an operator inserts the tongue 214 through the tongue opening 443 of the frame 430 to releasably engage the locking feature 680 of the frame 430, the tongue 214 contacts the tongue contact surface 456 of the locking member 450. During the initial insertion of the tongue 214 into the buckle assembly 110, the tongue 214 is positioned at an inclined angle relative to the frame 430. At this point, the engagement edge 219 of the pawl opening 217 is positioned below the locking feature 680 of the frame 430, and therefore not engaged with the locking feature 680.
Referring next to FIG. 9B, as the operator continues to insert the tongue 214 into the buckle assembly 110, the tongue 214 moves the locking member 450 out of the locked position. More specifically, the tongue 214 urges the tongue contact surface 458 of the locking member 450 to compress the coil spring 460 and move the locking member 450 out of the locked position. As the locking member 450 moves out of the locked position, the engagement locking edge 219 of the tongue 214 clears the corresponding locking edge 681 of the locking feature 680 of the frame 450. As shown in FIG. 9C, once the engagement edge 219 clears or passes the locking edge 681, the coil springs 460 drive the locking member 450 back toward the locked position. More specifically, after the engagement edge 219 clears the locking edge 681, the tongue 214 slides up the tongue contact surface 458 of the locking member 450 as the coil spring 460 biases the locking member 450 toward the locked position. In addition, as the tongue 214 slides up the tongue contact surface 458, the tongue 214 pivots about the tongue opening 443 in the tongue receiving portion 442 of the frame 430.
Referring next to FIG. 9D, the locking member 450 has returned to the locked position and securely retains the tongue 214 in a locked position against the locking feature 680 of the frame 430. More specifically, when the tongue 214 is fully inserted in the buckle assembly 110 with the locking member 450 in the locked position, the shelf 785 of the locking member 450 receives the tongue 214 to retain the engagement edge 219 against the locking edge 681. In this position, the locking feature 680 is positioned in the pawl aperture 217 of the tongue 214, and the tongue 214 is generally parallel with the frame 430. With the tongue 214 resting in the shelf 785 and the coil spring 460 biasing the locking member 450 in the locked position, the tongue 214 cannot disengage the locking feature 680 of the frame 430 until the button 220 moves the locking member 450 out of the locked position, as described in detail below with reference to FIGS. 9E-9H.
Referring next to FIG. 9E, when a user depresses the button 220 to release the connector 112 (e.g., by applying a force to the button 220 in a direction substantially toward to the frame 430), the ejection feature 888 of the button 220 drives the locking member 450 away from the tongue 214 and out of the locked position. More specifically, as the button 220 pivots downwardly, the locking member urging surface 893 slides against the button contact surface 456 of the locking member 450 and moves the locking member 450 out of the locked position.
Referring next to FIG. 9F, as the button 220 is further actuated or depressed, the ejection feature 888 presses against the tongue 214 to disengage the engagement edge 219 from the locking edge 681. As shown in FIG. 9G, once the button 220 moves the locking member 450 to the unlocked position, the engagement edge 219 clears the locking feature 680 of the frame 430 and the tongue 214 pivots about the tongue receiving opening 443 of the frame 430.
Referring next to FIG. 9H, once the button 220 is released, the coil springs 460 drive the locking member 450 back toward the locked position. Since the tongue 214 has disengaged the locking feature 680, the locking member 450 also automatically ejects or drives the tongue 214 out of the housing 222 as the locking member 450 moves back toward the locking position.
The embodiments of the buckle assembly 110 described above provide several advantages over conventional buckle assemblies. One advantage, for example, is that the locking member 450 securely retains the tongues 214 engaged with the locking features 680 when the locking member 450 is in the locked position. Another advantage is that the tongues 214 are positioned at an inclined angle with reference to the frame 430 when the tongues 214 are being inserted into or ejected from the buckle assembly 110. Moreover, when the tongues 214 are retained in the locked position, the tongues 214 are generally parallel to the frame. Accordingly, by the position of the tongues 214 relative to the frame 430 (e.g., at an inclined angle or generally parallel), a user can easily verify if the tongues 214 are securely retained in the buckle assembly 110.
From the foregoing, it will be appreciated that specific embodiments of the disclosure have been described herein for purposes of illustration, but that various modifications may be made without deviating from the spirit and scope of the various embodiments of the disclosure. Further, while various advantages associated with certain embodiments of the disclosure have been described above in the context of those embodiments, other embodiments may also exhibit such advantages, and not all embodiments need necessarily exhibit such advantages to fall within the scope of the invention. Accordingly, the disclosure is not limited, except as by the appended claims.
Patent Application
20110107560
