Energy absorbing connector

[0002] This application is a continuation of U.S. Pat. application 09/177,411, which was filed on Oct. 23, 1998 now abandoned.

[0003] The present invention relates to methods and apparatus for providing an energy absorbing connection between two members, such as a safety line and a support structure.

[0004] Energy absorbing connectors come in a variety of forms and are useful in a variety of applications. One type of energy absorbing connector is disclosed in U.S. Pat. No. 3,106,989 to Fuchs; U.S. Pat. No. 3,694,028 to Andres et al.; and U.S. Pat. No. 5,738,377 to Sugiki et al. These prior art arrangements connect a strip of metal between two members in a manner which causes the metal to tear when subject to force in excess of a threshold force. The shearing of the metal absorbs a significant amount of energy and reduces the likelihood of damage to the members and/or people in proximity to the members. This type of energy absorbing connector has been used on automobiles and in fall arrest systems.

[0005] With regard to the latter application, various occupations place people in precarious positions at relatively dangerous heights, thereby creating a need for fall-arresting safety apparatus. Such apparatus typically require a reliable safety line and reliable connections to the support structure and the person working in proximity to the support structure. One type of known fall arrest system connects a horizontal line to a support structure to support individual worker safety lines and minimally interfere with the worker's movements.

[0006] Examples of horizontal safety line systems are disclosed in U.S. Pat. No. 5,343,975 to Riches et al., U.S. Pat. No. 5,279,385 to Riches et al., U.S. Pat. No. 5,224,427 to Riches et al., and U.S. Pat. No. 4,790,410 to Sharp et al. An object of the present invention is to provide an improved energy absorbing connector for use at the ends of safety lines used in this type of system. Another object of the present invention is to provide an energy absorbing connector which strikes a good balance between energy absorbing capacity and cost effectiveness.

[0007] The present invention provides methods and apparatus for absorbing energy at a point of connection between two members. On a preferred embodiment of the present invention, a first end of a metal strip is separated into first and second tabs. At least one tear line is provided along an intermediate portion of the strip, from a point of separation between the tabs to a point proximate an opposite, second end. The second end of the strip is coiled inside the intermediate portion of the strip. The resulting connector absorbs energy both by tearing along the tear line and by uncoiling. Additional features and/or advantages of the present invention may become more apparent from the detailed description which follows.

[0008] With reference to the Figures of the Drawing, wherein like numerals represent like parts and assemblies throughout the several views,

[0009] FIG. 1 is a top view of a metal strip configured according to the principles of the present invention and manipulable into an energy absorbing connector;

[0010] FIG. 2 is a side view of the strip of FIG. 1;

[0011] FIG. 3 is a side view of an energy absorbing connector made from the strip of FIG. 1;

[0012] FIG. 4 is a top view of the connector of FIG. 3; and

[0013] FIG. 5 is a perspective view of a horizontal safety line system including the connector of FIG. 3.

[0014] A preferred embodiment connector constructed according to the principles of the present invention is designated as 100 and 100′ in FIGS. 1-5. The connector 100 is made from a metal strip 110, preferably stainless steel and approximately twenty-six inches long, three inches wide, and one-eighth of an inch thick. The strip 110 extends lengthwise between a first end 111 and a second end 112. Two lines of interruptions 117 extend parallel to one another along an intermediate portion 114 of the strip 110. The interruptions 117 divide the intermediate portion 114 of the strip 110 into an interior strip 137 disposed between opposite side strips 127. On the preferred embodiment 100, the interruptions are holes extending through the strip and having a diameter of one-eighth of an inch. Those skilled in the art will recognize that other interruptions, such as notches in one or both sides of the strip may be substituted for the holes without departing from the scope of the present invention. Each line of interruptions 117 starts at a point of separation between tabs 120 and 130 terminates at a relative larger hole 119 at the second end 112 of the strip 110. On the preferred embodiment 100, each larger hole 119 has a diameter of one-half of an inch.

[0015] The interruptions in the first line are longitudinally staggered relative to the interruptions in the second line. In FIG. 1, for example, the relatively larger hole at the end of the right line is separate from the relatively smaller interruptions, whereas the relatively larger hole at the end of the left line includes the last relatively smaller interruption in the line. Also, in FIG. 4, nine whole interruptions are shown in the left line, whereas eight whole interruptions and two fractional interruptions are shown in the right line.

[0016] A generally U-shaped cut 115 separates the first end 111 of the strip 110 into a first, outside tab 120, and a second, inside tab 130. A hole 121 extends through a central portion of the first tab 120 to receive a fastener, and a similar hole 131 extends through a central portion of the second tab 130 to similarly receive a fastener. The ends of the cut 115 are aligned with the lines of interruptions 117, and the middle of the cut 115 extends in arcuate fashion about the hole 131 at a radius equal to more than one-half the distance between the lines of interruptions 117.

[0017] The strip 110 may be manipulated into the configuration shown in FIGS. 3-4. The second end 112 of the strip 110 and a proximate part of the intermediate portion 114 are coiled or rolled up inside the remainder of the intermediate portion 114. Tabs 120 and 130 are bent in opposite directions away from the intermediate portion 114 so that they extend perpendicular thereto and parallel to one another. FIG. 4 shows the opening in the first tab 120 which is created by the removal of the second tab 130. The resulting connector 100′ is suitable for connection in series between two other members. The rolled-up arrangement of the connector 100′ is such that it occupies relatively little space while providing relative large energy absorption capacity. In particular, energy is consumed both by tearing of the metal strip 110 along the interruptions 117 and straightening of the metal strip 110 as the portions 127 and 137 tear away from one another.

[0018] A preferred application for the present invention 100 may be described with reference to horizontal safety line systems of the type disclosed in U.S. Pat. No. 5,343,975 to Riches et al., U.S. Pat. No. 5,279,385 to Riches et al., U.S. Pat. No. 5,224,427 to Riches et al., and U.S. Pat. No. 4,790,410 to Sharp et al., which are incorporated herein by reference. As shown in FIG. 5, the connector 100′ is connected in series between a support structure 20 and the end of a horizontal safety line 40. The horizontal line 40 is also supported by intermediate brackets 90. A personal safety line 70 is interconnected between a worker's harness and a slotted coupling member 80 which moves along the horizontal line 40. In the event of significant impact on the line, such as during a fall arrest, the connector 100′ absorbs some of the energy associated with the fall, and thereby reduces the likelihood of personal injury and/or damage to the most significant components of the system. A spent connector 100′ may be readily replaced by means of bolts or other fasteners connected through the holes 121 and 131 in the tabs 120 and 130, respectively.

[0019] Although the present invention has been described with reference to a preferred embodiment and a particular application, this disclosure will enable those skilled in the art to recognize additional embodiments and/or applications which fall within the scope of the present invention. For example, as suggested by the foregoing Background of the Invention, the present invention may be used in other environments, including automobiles. Thus, the scope of the present invention should be limited only to the extent of the following claims.