CA2155229A1 - Quick lift integrated safety harness - Google Patents

Abstract

The invention has achieved the ability to combine a fully padded safety harness with the required recreational or occupational garment through thermal foaming, foam lamination technologies and design. This results in an integrated safety harness that allows for greater application through a variety of fields. It consists of a two part waist belt construction with splice panels and exchangeable tie in points. An advanced leg loop design offers full padding, full adjustment and removability. In the event of a fall, correct load bearing capabilities exist. The Invention also grants the wearer the option of replacing the two structural parts, that are most susceptible to wear or damage through continuous use. The invention is to be used in any occupation or recreation where tying into a safety line, rope or lanyard is required.

Description

saaq RELATED APPLICATION

This application is separate from and does not offend patent applications U.S. Pat. No.
5,136,724 filed August 11, 1992 and U.S. Pat. No. 5,289,590 filed March 1, 1994 and are inForporated in C~n~ by reference.

215~229 -SPECIFICAl~ON

Backgloulld of the Invention The present invention relates to occupational and recreational clothing that have safety harnesses built in. The term "Integrated Safety Harness" is used here to describe such an lnvention.

An example of an earlier known integrated safety harness is described in a U.S. Patent #5,289,590. This patent specification of an integrated safety harness incllldes a safety harness that is secured on a liner in the form of innerwear trousers. It consists of a buttock support band whose end portions spiral up around the wearer's lower torso to above the wearer's waist in front and project out through slots below the waist in a pair of outerwear trousers. The ends of the support band comprise the "tie in point."

The term "tie in point" is used here to describe the point of a safety harness to which one is attached or secured to a safety line, rope or lanyard.

Although the patents harness webbing is secured to the liner of the pant, its design is that of a harness that does not lend itself to putting the wearer into a sitting position when weighted. Instead it causes the tie in point to be pushed into the ribcage and the leg webbing to ride up into the growing area c~ ing excessive discon~ol L to the wearer.

The tie in point itself is limited to a recreational use only, as a "nylon only" tie in point does not meet many of the safety standards and specifications of the construction or rescue industries. The design is also limited by its inability to adjust to the size and shape of the wearer, resulting in a loose fft (dangerous) or a fit that is too tight, c~lsing discomfort.

The patents design of positioning the waist belt buckle centre to the pant competes for space with the tie in point on the harness, this presents problems of congestion of space that can compromise safety and comfort.

Although this particular design offers ease of use to the wearer the harness design falls short in "load bearing" circumstances. The design supports the waist. This creates within the wearer the feeling of wanting to go over backwards when the harness is weighted which is dangerous. Pressure is also placed on the small of the back at the point of the kidneys when worn for long periods of time due to the narrow waist belt and no p~ ling. This patent offers no padding at any of the pressure points on the wearer's body that the harness webbing comes in contact with.

This patent is highly limite~l in its applications and can cause much discoll~l L to the wearer when weighted. If the wearer should fall unintentionally the harness design will not pull the body into the sitting position (the safest fall position), a position that distributes the load bearing force of the fall evenly throughout the harness.

2iS~229 -Another U.S. Patent #5,136,724 in Safety Harnesses is that of a Firefighters combination trouser and safety harness. Although this patent has several quality features, such as the ability to protect the structure webbing of the harness by means of an over pant and an ability to be fully adjustable, it also has limitations.

The patent design has left itself highly specialized to catering specifically to city firefighting where skyscrapers or buildings of that type are a concern. Although the h~rnes~ design of this patent is fully adjustable its drawbacks are apparent. As mentioned in the previous patent, being unpadded is a discomfort and the adjustment design is by no means quick.
The Outerpant has to be completely removed for correct adjustment to happen. The removal and zltt~shment of the outerpant lends itself to a labour intensive process that cannot be conducted in the field with any speed or efficiency.

This also brings up another issue of safety for the wearer, when considerable knowledge in the invention is needed to ensure its safe use. With the approach of safety towards a "shared harness" (a harness that is worn by more than one individual i.e. shift work), harness adjustment is an ongoing issue. This patent looses its ability to be donned quickly while ensuring fit and safety.

The fixed legs and absence of "rise strap" are also other concerns in the harness design. The fixed legs (the inability to adjust along the waist belt), present the problem of correct fit.
When having to adjust to a larger fit the front of the waist belt (the area of the tie in point) 21~2~9 is fixed in size. This brings the legloops forward, which in turn sends the legloop buckles closer into the growing area creating discomfort.

The term "rise strap" is used here to describe a structural component co~ lised of webbing that connects the waist belt to the legloops at the front of the harness for reasons of correct load bearing force distribution.

The absence of the rise strap allows the tie in point when weighted to ride up into the ribcage c~ ing the same problems the previous patent was faced with. Another discerning factor is the complexity of construction with all the parts involved in securing the harness to the pant. Not only is it difficult to construct, attach, and adjust, but it also creates a multitude of pressure points that cause discomfort to the wearer.

~'G ~ ~ '7 t 5 Other problem areas are the patent's waist belt is secured by a snap connector to the ~nmll~r connector member, a method that can be prone to opening if harness adjustment is not correct. In design the invention is unnecessarily heavy, cumbersome and uncomfortable.

21~5229 SUMMARY

It is desireable within the occupational and recreational fields to have a safety harness that:

meets all safety standards and specifications;
B. works with flexibility;
C. have simplicity in design, aiding in ease of underst~nlling and use;
D. have convenience and speed of application; and E. is light in weight and high in colllrol ~ when weighted or worn for extended periods of time.

Accordingly, the object of the present invention is to meet all of the above mentioned needs, as well as have the ability to be applied to a variety of uses and fields.

This invention comprises of a combination of a fully padded safety harness that can hold its shape, and the occupational or recreational garment to which it can be applied. The safety harness is integrated into the garment in such a manner that the harness also carries functions of the garment, and the garment that of the harness. The invention by its design and applied technologies caters to a greater range of fit, is light, flexible, desireable, and above all comfortable. The term "fully padded" is used here to describe the p~ ling that surrounds the structural webbing of the harness for reasons of COll~Ol L.

The invention offers the ability to replace the two structural parts of its harness that receive the most wear and damage through continuous use. It is also designed in the event of a fall to disperse the load bearing forces evenly throughout its harness.

In order to achieve the above listed objectives in the easiest possible manner, the introduction of new technologies and advances in harness design are needed.

By introducing thermal forming foam l~min~tion technology with design give the ability to simplify and expand the potential of the integrated safety harness. This process allows harness and garment to take on one identity. By this it is meant the construction is of such a manner that the harness also carries the functions of the clothing and vice versa. An inseparable integration of harness and garment results. The thermal forming foam l~min~tion technologies and design allow the integrated safety harness to be fully padded, adjustable, light in weight and g*e with the ability to cater to a variety of occupations or recreational uses.

Through the thermal process the integrated safety harness can be formed or moulded into a fixed shape. This ability to hold a desired shape offers the wearer the advantage of speed and ease in use and underst~n(ling when donning the harness.

Along with the thermal forming and foam l~min~tion technologies, the two part waist belt design with its "splice panels" and exchangeable tie in point open up the ability of catering to all occupational and recreational uses where securing to a fixed line rope or lanyard when safety is required.

The exchangeable tie in point carries the ability of integrated safety harness to meet and comply to a variety of safety standards and specifications that each field requires. The design and technologies of the integrated safety harness have the ability to be applied to any material and garment that is used in conjunction with the traditional harness in the desired occupational or recreational fields.

The integrated safety harness, with its advances in legloop design realizes the ability to offer a fully padded legloop that has the ability of full adjustment and the ability to be completely removed from the invention if required or desired. This creates an integrated safety harness with greater comfort, a larger range of fit and the ability of replacement of the structural webbing if damaged.

This is achieved by constructing the p~-ltling directly into the garment itself, while structural webbing being separate is threaded onto the padded legloop tabs and through the abrasion covers over the leg loop padding that is constructed into the garment.

21~229 -DIRECTIONS ON THERMAL FORMING FOAM LAMINATION
In construction of the above defined invention skills and experience in thermal forming and foam l~Tnin~tion are required. Processes can vary depending on method of approach, materials used and choice of press times and temperatures for l~min~tion, baking and pressing. Defined here in detail are the methods and processes involved in the construction of this particular prototype.

T ~min~tion Press The type of thermal l~min~tion press used is a hydraulic flat bed press. The press collsisL~
of a top and bottom plate construction. The top plate (heated) is secured to a hydraulic cylinder by four adjustable eye mounts, which in turn are secured to an overhead I-beam that is welded to the carriage or frame of the press. it is a 63" x 43" x 1/4" steel plate welded to a 3 1/2" x 1 1/2" steel bar frame. This frame has two ~U~Ull bars inset. The steel plate then has an ~h~ plate 62 1/2" x 43 1/2" x 1/4" in size that is suspended below in a floating manner. Heat elements are placed in rows parallel to the support bars on the back side of the top plate (six sets) and are covered with in~nl~tion.

The bottom plate (cold) is 63" x 43" x 1/4" and is welded to a steel bar frame equal to the top plate. It is fixed to the carriage or frame of the press and is covered with K126 1" open cell foam. It in turn is covered with a 65" x 45" teflon release sheet.

~O

21~22i~
-The carriage frame is of I-beam construction and mounted on wheels. It has two accompanying tables also on wheels that are level to the bottom plate of the press. They are positioned one on either end of the press. The press is constructed to be operated from one side only. The control panel has a two button operation for raising and lowering the top plates hydraulic cylinder. It has temperature and timing control.

Raw Material T ~rnin~tion Waist Belt Inside Panel The raw material plank of the waist belt inside panel comprises of EV50 foam 9mm x 60"
x 40" covered with Dow 899 glue film 61" x 41". It in turn is covered with 5476 14 oz fleece 62" x 43". The fleece is covered with a craft paper to keep glue from getting onto the press.
It is pressed for 25 seconds 2 times with a five second interval between pres~ing~, allowing for gases to escape, preventing the fabric from creasing. Press temperature is 180 degrees.

Waist Belt Outside Panel Place a sheet of Dow 709 glue film 61" x 41" overtop of a 2000 denier pure (Ballistics) 62"
x 42". Then cover the glue film with a teflon release sheet and press for 45 seconds at 145 degrees.

I~

2 1 S ~ 2 2 ~
-Leg Loop Foam Panel, Legloop Tab Panels and Tie in Point R~c~ine The legloop foam panel, tab panels and tie in point backing have a two side press instruction:

Side A

EV50 foam 6mm x 60" x 40" is covered with Dow 899 glue film 61" x 41", which in turn is covered with 5476 14 oz fleece 62" x 43". (Use the same l~min~tion instructions as that of the waist belt inside panel) Side B

Turn finished side over (side A) and cover with Dow 899 glue film, then cover the glue film with 500 denim press 62" x 43". (Use the same l~min~tion instructions as that of the waist belt inside panel) Waist Belt Outside Panel:
Oven time 4 mimltes at 180 degrees Press time 3 mimltes at 3300 p.s.i.

Leg Loop Foam Panel:

21~i229 Oven time 4 mimltes at 180 degrees Press time 3.5 min~ltes at 3300 p.s.i.

Oven and Hydraulic Clicker Press Upon completion of l~min~ting the raw material planks, the planks are cut down to size suited to the specified reproduction mold. Bake the cut portion of plank in the oven at the required temperature and time. Remove and place immediately into the IIydl~ulic Clicker Press, ontop of the reproduction mold and press as it cools, for the required time at the correct p.s.i. The pressed piece is then removed from the press and cut out, completing a panel ready for the first stages of sewing.

Reproduction Mold Making 1. Draft required panels of product.
2. Make blue prints - 2 copies.

3. Spray mount Blue Print #l onto #l m~nill~ pattern paper.

4. Cut out the pattern from the paper and transfer the pattern over to 1/4 medite board.

5. Using Blue Print #2, cut specified shape from sculpting foam and set to 1/4" medite board in position with the transferred pattern.
At this point seam allowance should be showing on the board.

215~229 6. Sculpt the foam to the desired shape, thickness or size.

7. Mask the outside edge of the seam allowance.

8. Cover the sculpted foam and seam allowance with Polyester Resin and Catalyst.

9. Construct a medite dam 1 1/2" to 2" thick to boarder the outside edge of the seam allowance. Securely fix the medite dam to the medite board, cal)lurh~g the mold.

10. Coat the inside walls of the dam and the mold with release wax.

11. Fill the dam with reproduction plastic.

12. Rotar level the surface of the reproductive plastic to that of the dam. Remove die from mold.

Second Bakin~ (molding or shapin~) Upon completion of the first stage of sewing, the waist belt and legloop panels are attached to the desired mandrel. They are then placed in the oven for re-expansion to shape. The oven time is 10 minlltes at 155 degrees.

Remove from the oven and let cool for 15 minlltes before removing from the mandrel and going to the second stage of sewing.

The mandrel used in this prototype was created from medite, ~h~"~ ""~ and screen mesh materials. It is cylindrical in shape. The outside diameter of the waist belt mandrel is 32 cm and its width is 10.5 cm. Each mandrel has two of these cylinders on a stand 30 cm in 21~'~2~9 -height. The waist belt is secured down to the cylinder by a nylon mesh strap that takes the shape of the waistbelt and covers it evenly. The strap secures firmly with even pressure the waist belt to the mandrel. The mandrel is hollow to allow for even distribution of heat to all parts of the waist belt. The legloop mandrel outside diameter is 23 cm and its width is 10.5 cm. The stand height is 30 cm.

All materials used on this invention are suited to change depending on the required application and safety regulation within the field of use. Materials listed and used here are specific to the prototype.

Tie in Point Figure lA and lB

The tie in point buckle being a single or double pass system, dictates whether the buckle is to be attached to the tie in point, as seen in Figure lA ( a double pass buckle) or whether it is to be attached onto the main panel of the waist belt after it is closed and turned. In this prototype a double pass buckle is used.

Figure lA - Recreational Tie in Point The rappel loop 1 is sewn in a loop and given structural stitching complying with the required safety standards. The tie in point backing 3, is bound along its edge with binding tape 6. The tie in point webbing 4, is then passed through the left and right buckles 5, and 213522g ` -covered in its centre with the abrasion cover 2, completing a "prepared" tie in point webbing 4 to the tie in point backing 3 at each side of the abrasion cover 2, just in front of the buckles 5.

The term "structural stitcllingll is used here to describe stitçlling of the type that will meet and comply to the safety specifications dictated (not necessarily the type shown in the invention diagrams).

Figure lB - Occupational Tie in Point The tie in point backing 3 is bound around its edges with binding tape 6. The D Ring 8, is then threaded with the D Ring Webbing 7 and set closed using structural stit~ing- Again using a structural stitch, secure the D Ring Webbing 7 around the tie in point webbing 4 in such a manner as to create a bottom loop that will accommodate legloop ~tt~çllment. Next the tie in point webbing 4 is attached with the buckles 5, to the tie in point backing 3 once more using structural stitching.

Figure 2 - Preparing the Waist Belt Main Panels Support tape 10 is set at each end of the Outside Main Panel 9 (glue film side). This is for protection from damage when turning the waist belt right side out. The support tape is set 1 cm in from the ends creating a "flap" that is used in later closing the ends of the 1~

21S~29 _ completed main panel [See Figure 5].

The inside main panel 11, is bound on one end with seam tape 12, on the other end support tape 10. The support tape 10, along with the edge of the inside main panel is then bound with seam tape 13, that is set in a circle that accommodates easy turning with the hook.

Figure 3 The Outside main panel 9 is then set with the Overlay webbing 14. As it is attached, steps are to be taken to allow for the later insertion of accessory rings, straps, loops, elastic retainers or other ~tt~ ments. As seen in Figure 3, 15 stitches were skipped to create the insertion hole.

Figure 4A - Closing the Main Panels Upon closing the outside main panel 9, to the inside main panel 11, splice panels 16 are placed onto the outside face of the outside main panel 9. Once set of two splice panels 16, are set flush to each edge as they are covered and set face down with the inside main panel 11. Both Outside and Inside main panels are set together down their lengths, keeping the ends open to create a "tube."

Figure 4B

-A hook is then passed through the tube and is hooked onto the seam tape loop 13 then pulled back out from the tube to turn the "waist belt tube" right side out. Once turned the "waist belt tube" should appear as in Figure 4D with a given profile at its centre of Figure 4C. At this point the flaps in Figure S are then inserted back into the ends and the "waist belt tube" is closed.

The closed waist is then placed onto the mandrel as described in the thermal 1~7nin~tion steps, baked to shape, and then removed from the mandrel for the second steps of the sewing construction.

Upper outside panels and liner panels of the garment along with its zipper are then set onto the waist belt each to its preferred splice panel 16 which in turn is taped for better wear.
A liner is optional, again the required application or field of uses will specify.

Leg Loop Construction Figure 6 - Leg Loop Webbings The legloop webbing 17, is folded and set at the point where it makes contact with the rise strap 18. The tails of the legloop webbing 17 are cut and sealed to accommodate easy threading of the buckles 21. The rise strap webbing 18, is folded and set onto itself from both ends creating loops for the leg loop webbing 17 to pass through. The tie in retainer l~

21~5~29 strap 19, with its buckle, is laid down in a manner that when covered with the rise strap abrasion cover 20, the buckle protruding from one end and with a considerable amount of the strap m~king a tail from the other end. The completed rise strap 17 is then threaded onto the legloop webbings 17 where buckles 21 are placed onto the webbing and secured with structural stitching. The rise strap 18, is then secured to the legloop webbing 17 with structural stitches. The rise strap 18, also receives structural stitches, completing the legloop webbing construction.

Legloop Tabs Figure 7 The legloop tab main panel n is set with elastic retainers 23 that later hold the legloop webbings in place. The legloop tab main panel 22 is then bound with seam tape 24 around all sides except the edge that is inset in the garment seam. The completed legloop tab æ
is then inserted adjacent to the legloop main panel 25 of the rear leg construction of the garment as seen in Figure 7. There are two tabs per leg.

The Legloop Main Panel Figure 8 The legloop main panel 25 is sewn into the garment along with the legloop tabs at each seam of the front 31 and rear 27, 29 panels on the legs of the garment in Figure 10. The legloop main panel abrasion cover 26 is set to the legloop main panel 25 down its length with each of the ends folded under for a finished edge. The ends of the abrasion cover 26 ;~
l~

21~S229 fall short of that of the main panels 25 and are left open to create a "tube," which enables the legloop webbing 17 to pass through. The upper 27 and lower 29 rear panels and liner panels 28 and 30 of the garment are then set to the legloop main panels 25 and given small structural stitches at all four corners where the abrasion cover 26 meets the garment, reinforcing the stress points created by the legloop webbing 17. The front panels 31 and liner of the garment legs are then set to the completed rear panels 26,27 and 29.

From this point trouser construction is completed via standard methods applicable to the industry. The completed trouser is then set to the bottom edge of the harness waist belt on the splice panels 16 using the same method as the upper garment.

~4 ~0 -LIST OF FIGURES

Figure lA Recreational Tie in Point Figure lB Occupational Tie in Point Figure 2 Waist Belt Main Panel Construction Figure 3 Waist Belt Accessory Insert Diagram Figure 4 Waist Belt Main Panel Assembly Figure S Waist Belt End Folds Diagram Figure 6 Leg Loop Structural Webbing Diagram Figure 7 Leg Loop Tabs Diagram Figure 8 Leg Loop Rear Panel Construction Figure 9 Rear 3/4 Profile Figure 10 Front View ~1

Claims (8)

1. An integrated safety harness that is fully padded and adjustable, with the ability to be applied to various occupational and recreational fields where the use of safety lines, safety ropes or safety lanyards are to be used.

2. An integrated safety harness as defined in claim 1, that through the use of thermal forming technologies and advances in design allow both harness and garment to take on one identity as it is constructed in such a manner that the harness also carries functions of the garment and vice versa.

3. An integrated safety harness as defined in claims 1 and 2, that through its design has the ability to replace structural components if damaged or job applications requires it.

4. An integrated safety harness as defined in claims 1, 2 and 3 that through the design of its waist belt splice panels allows for greater flexibility and more efficient means of harness and garment integration.

5. An integrated safety harness as defined in claims 1, 2, 3 and 4 that through the design of its two part waist belt construction allows for:

A. greater ease of construction for the manufacturer;
B. a greater range of use and applications with the ability to offer a choice of "tie in points;"
C. an ability to effectively reduce wear on its structural webbings, and D. the wearer has the ability to obtain and wear the invention in a faster and more efficient time, at the same time requiring less knowledge to apply correctly.

6. An integrated safety harness as defined in claims 1,2,3,4 and 5 that through its advances in legloop design and construction have the ability to:

A. fully pad all structural webbing parts that apply pressure to the body when weighted;
B. offer a fully adjustable structural legloop webbing that can accommodate all sizes and thickness of legs;
C. offer an abrasion cover that protects the structural legloop webbings from damage and also have the ability to eliminate the need for a rear hold up strap;
D. offers the ability to remove completely from the invention, the structural legloop webbing allowing for a greater freedom of movement by the wearer and the ability to replace if damaged.

7. An integrated safety harness as defined in claims 1,2,3,4,5 and 6 that through design of the padded leg tabs:

A. eliminates material binding and stress points that the structural webbings of the legloop place upon the garment reducing wear and discomfort;
B. fully pad and guides the legloop structural webbing for reasons of correct fit and comfort.

8. An integrated safety harness as defined in claims 1,2,3,4,5,6, and 7, that through design has the ability to:

A. be constructed into floatation suits, allowing for greater "on deck" safety and speed of retrieval with regards to overboard rescue;
B. be constructed in "city firefighting clothing" when applied to thermal and moisture protective materials offering a lighter and far more flexible choice for the wearer;
C. be constructed into Forestry Firefighting when helicopter rappel and evacuation are to be required;
D. lend itself to unmanned airlift of trained personal by means of helicopter in air-land and air-sea rescue or recovery;
E. in the case of rescue can be applied in the same manner as an evacuation sack;

F. be used on all marine and ocean going vessels, ships and boats where safety when working around high seas and winds is necessary;
G. be used in military and police applications when constructed with the required materials. Applications such as assaults, rescues, retrievals and training that involves exposed conditions are contemplated;
H. be applied to construction or rigging occupations and practices;
I. be applied to all avenues of climbing and caving when applied to the preferred materials;
J. be used in all levels and types of recreational and competitive sailing;
K. be used in avalanche patrol and rescue within the skiing industry.