U.S. patent application number 16/390765 was filed with the patent office on 2020-03-05 for lanyard coupler, system and method.
The applicant listed for this patent is SNUGZ/USA INCORPORATED. Invention is credited to Christopher J. Culley, Brandon R. Mackay.
Application Number | 20200069004 16/390765 |
Document ID | / |
Family ID | 69640794 |
Filed Date | 2020-03-05 |
United States Patent
Application |
20200069004 |
Kind Code |
A1 |
Mackay; Brandon R. ; et
al. |
March 5, 2020 |
Lanyard Coupler, System and Method
Abstract
A lanyard coupler for selective attachment to a lanyard strap
and an attachment member, the lanyard coupler including a body
having a first end and a second end, an arm portion being formed
toward the first end, the body tapering from the first end toward
the second end. A strap receiving opening extends across a portion
of the body, while a connector extends from the second end of the
body.
Inventors: |
Mackay; Brandon R.;
(Saratoga Springs, UT) ; Culley; Christopher J.;
(Saratoga Springs, UT) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
SNUGZ/USA INCORPORATED |
West Jordan |
UT |
US |
|
|
Family ID: |
69640794 |
Appl. No.: |
16/390765 |
Filed: |
April 22, 2019 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
62724334 |
Aug 29, 2018 |
|
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|
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
A44B 15/00 20130101;
A44B 17/0029 20130101; A45F 2005/006 20130101; A44B 17/0041
20130101; A45F 5/00 20130101; A44B 17/0023 20130101 |
International
Class: |
A44B 17/00 20060101
A44B017/00; A45F 5/00 20060101 A45F005/00 |
Claims
1. A lanyard coupler for selective attachment to a lanyard strap
and an attachment member, the lanyard coupler comprising: a body
having a first end and a second end, an arm portion being formed
toward the first end, the body tapering from the first end toward
the second end; a strap receiving opening extending across a
portion of the body; and a connector extending from the second end
of the body.
2. The lanyard coupler of claim 1, wherein the arm portion extends
in a cantilever fashion.
3. The lanyard coupler of claim 1, further comprising a chamfer or
tapered edge along a perimeter of the lanyard receiving
opening.
4. The lanyard coupler of claim 1, further comprising a chamfer or
tapered edge along a perimeter of the body.
5. The lanyard coupler of claim 1, wherein the lanyard receiving
opening comprises a first opening portion and a second opening
portion, the first opening portion having a first terminal end
having a generally curved profile and a second terminal end
terminating toward the second opening portion.
6. The lanyard coupler of claim 5, wherein the second opening
portion extends angularly from the first opening portion.
7. The lanyard coupler of claim 6, wherein the second opening
portion comprises a first portion and a second portion, the first
portion and the second portion being inclined relative to a
longitudinal axis of the body at different inclinations.
8. The lanyard coupler of claim 7, wherein the first portion
extends from the first opening portion and the second portion
extends from the first portion, the first portion being generally
parallel to the longitudinal axis and the second portion being
transverse to the longitudinal axis.
9. The lanyard coupler of claim 1, wherein the arm portion is
connected to a body portion at a first side of the body and
separated at a second side of the body.
10. The lanyard coupler of claim 9, wherein the arm portion has a
generally gooseneck shape with a hook portion at the second
side.
11. The lanyard coupler of claim 10, wherein the hook portion
comprises at least one lip adjacent a junction of a first portion
and a second portion forming the lanyard receiving opening.
12. The lanyard coupler of claim 11, wherein the at least one lip
extends towards the first side of the body.
13. The lanyard coupler of claim 11, wherein the second portion is
narrower adjacent the at least one lip than at a terminal end of
the lanyard receiving opening at the first side of the body.
14. The lanyard coupler of claim 1, wherein the body comprises an
enlarged portion adjacent the connector, the enlarged portion being
curved in a direction transverse to an axis of the body extending
from the first end to the second end.
15. The lanyard coupler of claim 1, wherein the body comprises a
roughened surface surrounding the lanyard receiving opening.
16.-20.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claim priority to and benefit of U.S.
Provisional Patent Application No. 62/724,334, filed 29 Aug. 2018,
and entitled LANYARD COUPLER WITH SONIC WELDING ATTACHMENT, the
disclosure of which is incorporated herein by reference.
BACKGROUND OF THE INVENTION
1. The Field of the Invention
[0002] The present invention is in the field of lanyards. More
specifically, the present invention relates generally to systems,
methods, and apparatus for coupling items to lanyards.
2. Background and Relevant Art
[0003] A lanyard is a cord, strap, line or other such member used
to hold or fasten to an object. Lanyards are commonly worn by
persons to secure items around their neck or body. One end of the
lanyard typically includes a connector and/or clip to which the
items can be attached, such as name tags, wallets, keys, lip balm,
or any other personal item. A variety of different lanyards and
lanyard connectors are presently available within the art.
[0004] A number of presently available lanyards and lanyard
connectors utilize multiple separate component parts that are
assembled together through many steps, some of which are difficult
to perform and can result in assembler fatigue. This results in an
increase in manufacturing time and the likelihood of error or
manufacturing difficulties. Furthermore, using multiple separate
components parts results in a more unwieldy or cumbersome lanyard
or lanyard system. As such, there are a number of disadvantages in
the art that can be addressed.
BRIEF SUMMARY OF THE INVENTION
[0005] Implementations of the present invention solve one or more
problems in the art with systems, methods, and apparatus for
coupling items to lanyards. In particular, the present invention
relates to a lanyard system having a lanyard coupler that receives
a lanyard at one end and is selectively attachable or mountable to
an attachment member on the other end. A lanyard coupler can
include a body having a first end and a second end, an arm portion
being formed toward the first end, with the body tapering from the
first end toward the second end. A strap receiving opening extends
across a portion of the body, while a connector extending from the
second end of the body. Optionally, the arm portion can have a
generally gooseneck shape with a hook portion.
[0006] In another configuration, the lanyard system includes a
coupler having a body with an elongate slit extending across at
least part of the body near a proximal end, the slit forming a
proximal arm portion extending across the body proximal to the
elongate slit. A connector extends away from the distal end of the
body. The lanyard strap received within the slit has a weld that
secures at least three layers of the lanyard strap together, thus
forming a loop at a distal end of the lanyard strap.
[0007] In still another configuration, the lanyard system can be
formed through an assembly method that includes providing a coupler
and providing a lanyard strap. The coupler includes a lanyard strap
receiving opening extending across a body near a proximal end of
the body, the lanyard strap receiving opening forming an arm
portion at the first end of the body. The lanyard strap has a loop
formed by overlapping portions of the strap substrate and then
forming a weld or welding the overlapping portions together, such
as through a thermal or ultrasonic welding process. With the
provided coupler and strap, the method includes attaching the
lanyard strap to the coupler by inserting the lanyard strap into
the lanyard strap receiving opening so that the lanyard strap
passes through the lanyard strap receiving opening and the arm
extends through the loop.
[0008] In another configuration, the arm portion of the coupler is
connected to a body portion at a first side of the body and
separated at a second side of the body. In so doing, the arm
portion can extend in a cantilever fashion from a remainder of the
body and form the lanyard strap receiving opening. Optionally,
repeated protrusions or a roughened surface can be formed along all
or a portion of the walls forming the lanyard strap receiving
opening and so can surround the lanyard strap receiving
opening.
[0009] In another configuration, a perimeter of the coupler
includes a chamfer or tapered edge. The chamfer or tapered edge can
extend along an entire length of the perimeter or along only a
discrete portion of the perimeter, such as along all or a portion
of the lanyard receiving opening, along all or a portion of the
outer surface of the body, or some other combination.
[0010] In another configuration, the lanyard strap receiving
opening can include a first opening portion and a second opening
portion, the first opening portion having a first terminal end
having a generally curved profile and a second terminal end
terminating toward the second opening portion. The second opening
portion can extend angularly from the first opening portion.
Optionally, the second opening portion can have a first portion and
a second portion, the first portion and the second portion being
inclined relative to a longitudinal axis of the body at different
inclinations. In another configuration, the first portion can
extend from the first opening portion and the second portion
extends from the first portion, the first portion being generally
parallel to the longitudinal axis and the second portion being
transverse to the longitudinal axis.
[0011] In still another configuration, the first portion and the
second portion of the second opening portion can include at least
one lip or protrusion, such as adjacent a junction of a first
portion and a second portion forming the lanyard receiving opening.
The at least one lip can form a narrow portion to the passageway of
the second opening portion.
[0012] Additional features and advantages of exemplary
implementations of the invention will be set forth in the
description which follows, and in part will be obvious from the
description, or may be learned by the practice of such exemplary
implementations. The features and advantages of such
implementations may be realized and obtained by means of the
instruments and combinations particularly pointed out in the
appended claims. These and other features will become more fully
apparent from the following description and appended claims or may
be learned by the practice of such exemplary implementations as set
forth hereinafter.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] In order to describe the manner in which the above-recited
and other advantages and features of the invention can be obtained,
a more particular description of the invention briefly described
above will be rendered by reference to specific embodiments thereof
which are illustrated in the appended drawings. Understanding that
these drawings depict only typical embodiments of the invention and
are not therefore to be considered to be limiting of its scope, the
invention will be described and explained with additional
specificity and detail through the use of the accompanying drawings
in which:
[0014] FIG. 1 illustrates a lanyard strap secured to a lanyard
coupler according to an implementation of the present
disclosure;
[0015] FIG. 2 illustrates a lanyard strap secured to a lanyard
coupler according to an implementation of the present disclosure,
with an attachment rotatably coupled to the lanyard coupler;
[0016] FIG. 2A illustrates a side view of the lanyard strap
according to an implementation of the present disclose;
[0017] FIG. 3A is a top plan view of the lanyard coupler of FIG.
1;
[0018] FIG. 3B is a bottom plan view of the lanyard coupler of FIG.
1;
[0019] FIG. 3C is side view of the lanyard coupler of FIG. 1;
[0020] FIG. 3D is another side view of the lanyard coupler of FIG.
1;
[0021] FIG. 3E is a rear end view of the lanyard coupler of FIG.
1;
[0022] FIG. 3F is a front end view of the lanyard coupler of FIG.
1;
[0023] FIG. 4 is a close-up view of a portion of the lanyard
coupler of FIG. 1;
[0024] FIG. 5A is a top plan view of another lanyard coupler
according to an implementation of the present disclosure;
[0025] FIG. 5B is a bottom plan view of another lanyard coupler
according to an implementation of the present disclosure;
[0026] FIG. 5C is side view of another lanyard coupler according to
an implementation of the present disclosure;
[0027] FIG. 5D is another side view of another lanyard coupler
according to an implementation of the present disclosure;
[0028] FIG. 5E is a rear end view of another lanyard coupler
according to an implementation of the present disclosure;
[0029] FIG. 5F is a front end view of another lanyard coupler
according to an implementation of the present disclosure;
[0030] FIG. 6 is a close-up view of a portion of another lanyard
coupler according to an implementation of the present disclosure;
and
[0031] FIG. 7 is a perspective view of a lanyard strap secured to a
lanyard coupler of FIG. 1.
[0032] FIG. 8 is a perspective view of an intermediate coupler
according to an implementation of the present disclosure.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0033] One or more specific embodiments of the present disclosure
will be described below. In an effort to provide a concise
description of these embodiments, some features of an actual
embodiment may be described in the specification. It should be
appreciated that in the development of any such actual embodiment,
as in any engineering or design project, numerous
embodiment-specific decisions will be made to achieve the
developers' specific goals, such as compliance with system-related
and business-related constraints, which may vary from one
embodiment to another. It should further be appreciated that such a
development effort might be complex and time consuming, but would
nevertheless be a routine undertaking of design, fabrication, and
manufacture for those of ordinary skill having the benefit of this
disclosure.
[0034] One or more embodiments of the present disclosure may
generally relate to manufacturing and using lanyard systems. A
lanyard system may allow individuals to securely retain personal
items, such as name tags, wallets, keys, lip balm, or any other
personal item. For instance, personal items can be retained by
attachment members that are in-turn coupled to a lanyard coupler
and a lanyard strap of the lanyard system. The lanyard coupler
described herein provides an easy to use coupler to which a user
can conveniently couple a lanyard strap. The coupler, and the strap
itself, is simple to manufacture to allow interchangeability of
couplers, straps, and attachment members. This offers a system that
conveniently accommodates a variety of different attachments,
straps, and couplers.
[0035] While the present disclosure will describe a particular
implementation of the lanyard system, it should be understood that
the devices, systems, and method described herein may be applicable
to uses. Additionally, elements described in relation to any
embodiment depicted and/or described herein may be combinable with
elements described in relation to any other embodiment depicted
and/or described herein.
[0036] Referring now to the FIG. 1 illustrated is a lanyard system
8 that includes a lanyard substrate or strap 10 secured to a
lanyard coupler 12, which in-turn cooperates with an attachment
member 14. For purposes of the present disclosure, a proximal end
or direction denotes portions of the coupler and/or strap that are
closer to the user's neck when the strap is worn thereabout, and a
distal direction refers to portions further away from the neck of
the user. For example, as seen in FIG. 1, a distal end 16 of the
strap 10 is shown secured to a proximal portion 18 of the coupler
12, while the attachment member 14 cooperates with a distal portion
20 of the coupler 12 as shown in FIG. 2, which will be discussed in
greater detail hereinafter.
[0037] The strap 10 extends from the coupler 12 and receives a
portion of the coupler 12 within a loop 22 at the distal end 16 of
the strap 10 so that at least a portion of the strap 10 overlaps a
portion of the coupler 12 when it is received within the loop 22.
The loop 22 is formed by overlapping portions or layers of the
strap 10, with three layers of strap 10 being joined together in
the configuration illustrated in FIG. 1. A single elongate length
of lanyard substrate forms the loop 22 and also a loop 122
receiving the user's neck (see FIG. 7). While three layers of strap
10 are joined together in the illustrated configuration, one
skilled in the art would understand that two or more layers can be
overlapped to form one or more loops depending upon the particular
needs of the strap 10. For instance, if the strap were to include
two loops, four or more layers could be joined together.
[0038] FIG. 2A depicts the strap 10 overlapping itself to form the
loop 22. As illustrated in FIG. 2A, a first end portion 24 of the
strap 10 is positioned between the second end portion 26 of the
strap 10 and an intermediate portion 28 of the strap 10, in a
direction transverse to a direction in which the intermediate
portion 28 extends to form the loop 122 receiving the user's neck
(see FIG. 7). For instance, the first end portion 24, the second
end portion 26, and the intermediate portion 28 overlap in a
direction A, while the intermediate portion 28 extends in direction
B.
[0039] In the illustrated embodiment of FIG. 2A, the first end
portion 24, the second end portion 26, and the intermediate portion
28 are joined together to form the loop 22 at the joint region 30.
When the substrate for the strap 10 is formed of a polyester,
nylon, or other thermoplastic polymer and composite the joint
region 30 is a weld. The weld can be formed in a number of ways,
including, but not limited to, the use of ultrasonic welding, melt
welding, or the like. Alternatively, or in addition to welding, the
joining of the layers of the strap 10 at the joint region 30 can be
achieved through adhesives, stitching or other mechanical
fasteners, such as when the strap 10 is formed of a material other
than thermoplastic polymers and composites. The use of welding,
however, beneficially decreases manufacture time and increases
manufacture productivity by providing a simple and repeatable
approach to forming the loop 22 and, more generally, the strap 10
of the lanyard system 8.
[0040] Returning to FIG. 1, the lanyard coupler 12 has a
substantially flat body 40 which can lay in a relatively flat
fashion when the strap 10 and the coupler 12 are worn by a user. A
body 40 of the coupler 12 has a first proximal end 42 and a second
distal end 44, with the body 40 tapering from the first proximal
end 42 towards the second distal end 44. A strap receiving opening
46 extends across a portion of the body 40 and separates the body
40 into an arm portion 50, which can be received within the loop 22
of the strap 10, and a body portion 52 from which extends a
connector 54 that allows convenient connection to many different
attachments, such as attachment member 14 and attachment 14' (FIG.
7). The attachment 14 is illustrated in a detached orientation in
FIG. 1 and an attached orientation in FIG. 2. The attachment member
14 is a clip-like attachment, while the attachment member 14' is a
loop-like or ring-like attachment (See FIG. 7). The discussion
related to the attachment member 14 is also applicable to the
attachment member 14' (See FIG. 7). Additionally, instead of
connecting directly to the attachment member 14, the coupler 12 can
attached to an intermediate adapter 130 (see FIG. 8) disposed
between the attachment member 14 and the coupler 12. This
intermediate adapter 130 can increase a separation distance between
the attachment member 14 and the coupler 12, thereby providing
alternate user access to the item held by the attachment member 13,
such as name tags, wallets, keys, lip balm, or any other personal
item.
[0041] With continued reference to FIG. 1, the connector 54 extends
from the second distal end 44 of the coupler 12. As illustrated, in
proximity to a location from which the connector 54 extends, the
body 40 includes reinforcement portions 68 that provide additional
structural support to the distal end 44. A reinforcement portion 68
is formed on either side of the body 40, although only one
reinforcement portion 68 may be include in alternate
configurations. Reference will be made to one of the reinforcement
portions, however, the discussion is also applicable to the other
reinforcement portion.
[0042] The reinforcement portion 68, as illustrated in FIGS. 1 and
3A-3F, is a raised portion elevated in relation to a generally
planar surface 48 of the outer surface of the body 40. A surface of
the reinforcement portion 68 curves towards a first side 64 and a
second side 66, while also curving from the distal end 44 towards
the proximal end 42. A transition 78 between the reinforcement
portion's surface and a remainder of the body 40 has a generally
semicircular form, however, other shapes or forms of transition can
be used. For instance, transitions having other curved
non-semicircular forms or other non-curved forms of are possible.
Additionally, while the transition 78 terminates distal the strap
receiving opening 46 in a distal-to-proximal direction, in
alternate configurations, at least a portion of the transition 78
is coincident or corresponds to an inner edge of the strap
receiving opening 46 in the distal-to-proximal direction.
Similarly, while the transition 78 terminates remotely from the
first side 64 and the second side 66 in a direction transverse to
the distal-to-proximal direction, in other configurations the
transition 78 can be the first side 64 and/or the second side
66.
[0043] Returning to FIG. 1, the connector 54 is configured as a
male portion of a male/female connection between the connector 54
and the attachment member 14. The connector 54 is removably
connected to a complementary female portion of the attachment
member 14. The connector 54 may, for example, be secured to an item
that can then be selectively and removably connected to the coupler
12 shown. Other embodiments of the connector 54 may include other
male and/or female connection types that enable the coupler 12 to
be removably connected to items having complimentary connections
secured thereto.
[0044] The connector 54 has two spaced apart members 56a, 56b that
collectively form the connector 54 to which the attachment member
14 can be selectively coupled and about which the attachment member
14 can selectively rotate. The members 56a, 56b flex inwardly when
being mounted to a base 70 of the attachment member 14, then flex
outwardly to maintain (e.g., temporarily) the members 56a, 56b
within the base 70. It is possible to detach the attachment member
14 from the coupler 12 upon applying sufficient force to move the
parts apart e.g., by bending or otherwise manipulating the coupler
12 with respect to the attachment member 14 and pulling the parts
apart.
[0045] Each member 56a, 56b includes a narrow portion 58a, 58b and
an enlarged portion 60a, 60b. The narrow portion 58a, 58b has a
generally semicircular cross-section, while the enlarged portion
60a, 60b tapers from the narrow portion 58a, 58b toward an end 62
of the connector 54. The generally semicircular cross-section
allows rotational movement of the attachment member 14 relative to
the coupler 12, aiding with comfortable positioning of the coupler
12 and an item supported by the attachment member 14 for the
user.
[0046] With reference to FIGS. 1 and 2, in one embodiment, the base
70 of the attachment member 14 includes an interior diameter
portion 72 that is complementary to the connector 54. For instance,
the interior diameter portion 72 of the base 70 is tapered to allow
convenient mounting of the attachment member 14 onto the connector
54. The interior diameter portion 72 can, however, be
non-tapered.
[0047] Slot 74a, 74b are formed in the base 70 thereby forming
locking rim 76a, 76b to which the enlarged portions 60a, 60b
contact as they flex outwardly. A portion of each enlarged portion
60a, 60b enters a respective one of the slots 74a, 74b so that a
proximally facing portion of the enlarged portions 60a, 60b overlap
with and engage with the locking rims 76a, 76b to prevent
inadvertent detachment of the attachment member 14 from the
connector 54 of the coupler 12. However, as mentioned above, it is
possible to detach the attachment member 14 from the coupler 12
upon applying sufficient force to move the parts apart e.g., by
bending or otherwise manipulating the coupler 12 with respect to
the attachment member 14 and pulling the parts apart, causing the
members 60a, 60b to move off the locking rims 76a, 76b and out of
the base 70.
[0048] Turning to FIGS. 3A-3F and 4, illustrated is one embodiment
of the coupler 12 with the strap receiving opening 46 positioned
between the arm portion 50 and the body portion 52. The arm portion
50 is partially separated from the body portion 52 by the strap
receiving opening 46. Stated another way, the arm portion 50
extends from the body portion 52 in a cantilever fashion with the
strap receiving opening 46 being disposed between the arm portion
50 and the body portion 52. The arm portion 50 is connected to the
body portion 52 on a first side 64 and separated from the body
portion 52 on the second side 66. The arm portion 50 and the body
portion 52 defining the form and configuration of the strap
receiving opening 46. For instance, with the arm portion 50 having
an elongate portion 80 and a hook portion 82, thereby forming a
generally gooseneck shape, and the body portion 52 having a
complementary form, the strap receiving opening 46 provides a space
into which the strap 10 can be inserted and secured to the coupler
12, as illustrated in FIG. 4. It will be understood, however, that
the arm portion 50 can have other forms and shapes and the body
portion 52 can have complementary and non-complementary forms that
provide strap receiving openings of different forms or shapes while
still providing a space for securely retaining the strap 10.
[0049] The strap receiving opening 46 includes a first opening
portion 90 and a second opening portion 92. The first opening
portion 90 has a first terminal end 94 and a second terminal end 96
terminating toward the second opening portion 92. The first opening
portion 90 extends horizontally at least partially across a body 40
of the coupler 12 at or near the first proximal end 42 of the
coupler 12. In the illustrated configuration, each of the first
terminal end 94 and the second terminal end 96 have a curved
profile to accommodate the edges of the strap 10. For instance, to
aid with retaining in the strap 10 within the strap receiving
opening 46, an edge 32 of the strap 10 fits within the curved
profile to provide a tight fit and limit lateral movement of the
strap 10 relative to the coupler 12. While the curved profile can
approximate the size and dimension of the strap 10 and edge 32, it
will be understood by one skilled in the art that in other
configurations the curved profile need not approximate the strap 10
and edge 32.
[0050] Extending from the first opening portion 90 is the second
opening portion 92, as illustrated in FIG. 4. The second opening 92
extends away from the first opening portion 90 as a passageway or
angled passageway that communicates with the first opening portion
90 and a perimeter 98 of the body 40. The second opening portion 92
allows access to the first opening portion 92 into which the strap
10 is inserted, while the orientation of the second opening
prevents inadvertent removal of the strap 10 from the first opening
portion 92.
[0051] As illustrated, the second opening portion 92 includes a
first portion 100 and a second portion 102 that is slanted relative
to the first portion 100. The first portion 100 can also be
inclined relative to the first opening portion 90 or can be
perpendicular to the first opening portion 90. Stated another way,
the combination of the first portion 100 and the second portion 102
forms an angled passageway that extends from the first opening
portion 92 in a proximal-to-distal direction, i.e., downwardly.
Alternatively, the combination of the first portion 100 and the
second portion 102 forms an angled passageway that extends from the
first opening portion 92 in a distal-to-proximal direction, i.e.,
upwardly. In either case, the first portion 100 can be transverse
to the first opening portion 90 (such as transverse to an axis
extending in the proximal-to-distal direction, such as a
longitudinal axis) or perpendicular to the first opening portion 90
(such as parallel to the axis extending in the proximal-to-distal
direction, such as the longitudinal axis) and the second portion
102 can be transverse or perpendicular to the first portion 100,
which results in the second portion being transverse to or
perpendicular to the axis extending in the proximal-to-distal
direction, such as a longitudinal axis.
[0052] To form the first portion 100 and the second portion 102,
the arm portion 50 includes a wall 110 extending from the second
terminal end 96 and a wall 112 that is slanted relative to the
first wall 110. The junction of the wall 110 and wall 112 forming a
lip 118 that provides resistance to a movement of the strap 10 out
of the strap receiving opening 14. Similarly, the body portion 52
includes a wall 114 extending from the first opening portion 90 and
a wall 116 that is slanted relative to the wall 114. The walls 110,
114 define a perimeter of the first portion 100 of the second
opening portion 92, while the walls 112, 116 define a perimeter of
the second portion 100 of the second opening portion 92.
[0053] The embodiment of FIGS. 3A-3F and 4, the coupler 12 has a
smooth transition between the walls 110, 112 and so the lip 118 so
that the second opening portion 92 between the wall 110 and wall
112 and between the wall 114 and 116 form a generally uniform
cross-section. Stated another way, the passageway of the second
opening portion 92 has a generally uniform cross-section along its
length. It will be understood, however, that the slant of the walls
110-114 can vary so that the second opening portion 92 can have
different configurations. For instance, as illustrated in FIGS.
5A-5F and 6, the lip 118' of the coupler 12' is more pronounced
than the lip 118 and extends inwardly towards the body portion 52',
thereby narrowing the second opening portion 92' at a location
closer to the first opening portion 90' as compared with a location
of the second opening portion 92' closer to the perimeter 98'. The
second opening portion 92', therefore, tapers from the first
opening portion 90' to the perimeter 98'.
[0054] A lip 124' is formed across the second opening portion 92'
from the lip 118'. The combination of the lip 118' and the lip 124'
collectively narrows the second opening portion 92' close to the
first opening portion 90 to prevent the strap 10 becoming
inadvertently detached from the coupler 12'. It will be understood,
that in other embodiments, the coupler can include only the lip
118' or only the lip 124', rather than both lips. The second
opening portion 92' can be narrowed by about 35 percent to about 40
percent as compared to the end of the second opening portion 92' at
the perimeter 98' of the body 40' by the lip 118', the lip 124', or
a combination of the lip 118' and the lip 124'. Alternatively, the
second opening portion 92' can be narrowed by about 10 percent to
about 90 percent, by about 20 percent to about 80 percent, by about
30 percent to about 70 percent, by about 65 percent to about 90
percent, by about 20 percent to about 35 percent, by about 40
percent to about 65 percent, or by about 10 percent to about 20
percent.
[0055] While the embodiments illustrated in FIGS. 5A-6 include the
lip 118' and the lip 124' near the junction between the first
opening portion 90', it will be understood that one or both of the
lip 118' and the lip 124' can be disposed part way along the second
opening portion 92'. This provides an alternate manner to limit the
possibility of the strap 10 becoming dislodge or exiting the second
opening portion 92' because it has to pass two differently
positioned lips and move in two different directions, i.e., past
one lip towards the side of the coupler and then move past the
other lip in a direction away from the side of the coupler. The lip
118', therefore, can be closer to the perimeter 98' than to the
first opening portion 90' or the lip 124' can be closer to the
perimeter 98' than to the first opening portion 90'.
[0056] Additionally, while reference is made to the lip 118' and
the lip 124' being opposite to each other across the second opening
portion 92', the lip 118' and the lip 124' can be offset from each
other along the second opening portion 92'. This results in the
second opening portion 92' has a serpentine, bending, tortuous, or
twisting form. For instance, with the lip 118' near the first
opening portion 90' the lip 124' is closer to the perimeter 98'
than the lip 118' to form the serpentine, bending, tortuous, or
twisting second opening portion 92'. Similarly, with the lip 124'
near the first opening portion 90' the lip 118' is closer to the
perimeter 98' than the lip 124' to form the serpentine, bending,
tortuous, or twisting second opening portion 92'.
[0057] In addition to the couplers 12, 12' described and shown
herein, one or more embodiments of a coupler 12 can also include
one or more protrusions 120 within the strap receiving opening 46,
including one or both of the first opening portion 90 and the
second opening portion 92. For example, a plurality of repeated
protrusions 120, or "teeth," can be formed along the inside edge or
edges of the strap receiving opening 46. The protrusions increase
the surface area and frictional contact between the strap 10 and
the inside edge or edges of the strap receiving opening 46 to form
a more secure connection therebetween. The protrusions can be any
number or combination of shapes, including triangular or
semicircular protrusions that run along the inside edge or edges of
the strap receiving opening 46. Alternatively, all or portions of
the strap receiving opening 46, and more generally the body 40, can
be roughened or textured to change the frictional engagement
between the coupler 12 and the strap 10. Stated another way, all or
portions of the strap receiving opening 46, and more generally the
body 40, can receive a surface finish to provide desired frictional
engagement between the coupler 12 and the strap 10 and/or the
coupler 12 and the attachment member 14. For instance, a surface
finish to aid with rotational movement of the attachment member 14
about the connector 54 can be applied to one or both of the
attachment member 14 and the connector 54, such as applying a
TEFLON coating or other low friction coatings. Alternatively, to
prevent unwanted movement between the strap 10 and the coupler 12,
an appropriate surface finish, such as the protrusions 120 or other
roughening surface technique, can be applied to limit movement of
the strap 10 within the strap receipting opening 46.
[0058] As mentioned above, each of the couplers can either directly
or indirectly connect to the attachment member. For an indirect
connection, the intermediate adapter 130 can be used. As
illustrated in FIG. 8, the intermediate adapter 130 includes an
adapter body 132 extending between a connector 154 and a base 170
having similar configurations to the connector 54 and base 70 of
the coupler 12 and the attachment member 14. The description of the
connector 54 and the base 70 are also applicable to the connector
154 and the base 170 of the intermediate adapter 130. The adapter
body 132 can be fabricated from a material similar to the strap 10
or alternatively can be formed of a less flexible material, such as
material used to form the couplers 12, 12' or the attachment member
14.
[0059] To manufacture the lanyard system, the strap 10 is welded to
form the loop 22 prior to coupling the strap 10 and coupler 12
together. In another embodiment, the strap 10 is first threaded
through the strap receiving opening 46 and then the loop 22 is
formed by welding the together the first end portion 24, the second
end portion 26, and the intermediate portion 28 of the strap 10
together. Additionally, or alternatively, the joint region 30 is
provided closer to the proximal arm 20 of the coupler 12 so that
the loop is tightly formed around the arm portion 50. In such an
embodiment, the loop 22 of the strap 10 may be too small to be
moved through the second opening portion 82 and from the coupler
12, thus securing the strap 10 to the coupler 12.
[0060] For example, in one embodiment, the strap 10 is welded to
form the loop 22 of a first size. The arm portion 20 is then
inserted through the loop 22, and then a second weld 30' (FIG. 7)
is formed just proximal to the arm portion 20, as described above,
decreasing the size of the loop 22 to a size that more closely
approximates a diameter of the arm portion 22. Also, for example,
in one embodiment, the strap 10 is threaded through the strap
receiving opening 46, before any welds are provided, and then a
single weld 30 is provided just proximal to the proximal arm 20 of
the coupler 12 so that a tight loop around the proximal arm 20 is
formed. One will appreciate, from the embodiments described herein,
that any number of joint regions can be formed along the length of
the strap 10, proximal to the coupler 12, either before or after
the strap 10 is secured within the strap receiving opening 46.
[0061] Generally, the strap, coupler, and the attachment member can
each have a variety of sizes and shapes according to various
implementations of the present disclosure. The dimensions noted
herein are meant for illustrative purposes only and represent
non-limiting examples of the various sizes of straps, couplers, and
the attachment members that may be achieved or used. One skilled in
the art will appreciate that a manufacturer can form the strap,
coupler, and attachment member to have different sizes, shapes,
configurations, and relative dimensions.
[0062] Additionally, the strap, coupler, and the attachment member
can be fabricated from a variety of materials. For instance, and
not by way of limitation, the coupler and attachment member can be
molded or otherwise formed of various materials, including metals,
plastics, rubbers, and other materials and manufacturing methods
commonly known in the art. For instance, injection molding of
DELRIN or CELCON plastic is one method for manufacturing the
coupler and/or the attachments members. The materials and
manufacturing methods that form the strap can include polyesters,
nylons, cotton, or other natural or synthetic materials commonly
used in the art. Ends of the strap can be rounded, square, or a
variety of different shapes.
[0063] The articles "a," "an," and "the" are intended to mean that
there are one or more of the elements in the preceding
descriptions. The terms "comprising," "including," and "having" are
intended to be inclusive and mean that there may be additional
elements other than the listed elements. Additionally, it should be
understood that references to "one embodiment" or "an embodiment"
of the present disclosure are not intended to be interpreted as
excluding the existence of additional embodiments that also
incorporate the recited features. Numbers, percentages, ratios, or
other values stated herein are intended to include that value, and
also other values that are "about" or "approximately" the stated
value, as would be appreciated by one of ordinary skill in the art
encompassed by embodiments of the present disclosure. A stated
value should therefore be interpreted broadly enough to encompass
values that are at least close enough to the stated value to
perform a desired function or achieve a desired result. The stated
values include at least the variation to be expected in a suitable
manufacturing or production process, and may include values that
are within 5%, within 1%, within 0.1%, or within 0.01% of a stated
value.
[0064] A person having ordinary skill in the art should realize in
view of the present disclosure that equivalent constructions do not
depart from the spirit and scope of the present disclosure, and
that various changes, substitutions, and alterations may be made to
embodiments disclosed herein without departing from the spirit and
scope of the present disclosure. Equivalent constructions,
including functional "means-plus-function" clauses are intended to
cover the structures described herein as performing the recited
function, including both structural equivalents that operate in the
same manner, and equivalent structures that provide the same
function. It is the express intention of the applicant not to
invoke means-plus-function or other functional claiming for any
claim except for those in which the words `means for` appear
together with an associated function. Each addition, deletion, and
modification to the embodiments that falls within the meaning and
scope of the claims is to be embraced by the claims.
[0065] The terms "approximately," "about," and "substantially" as
used herein represent an amount close to the stated amount that
still performs a desired function or achieves a desired result. For
example, the terms "approximately," "about," and "substantially"
may refer to an amount that is within less than 5% of, within less
than 1% of, within less than 0.1% of, and within less than 0.01% of
a stated amount. Further, it should be understood that any
directions or reference frames in the preceding description are
merely relative directions or movements. For example, any
references to "up" and "down" or "above" or "below" are merely
descriptive of the relative position or movement of the related
elements.
[0066] The present invention may be embodied in other specific
forms without departing from its spirit or essential
characteristics. The described embodiments are to be considered in
all respects only as illustrative and not restrictive. The scope of
the invention is, therefore, indicated by the appended claims
rather than by the foregoing description. All changes that come
within the meaning and range of equivalency of the claims are to be
embraced within their scope.
* * * * *