BUCKLE ASSEMBLY AND METHODS OF USE

Abstract

A buckle assembly comprising a buckle body having an engaging element, a base body having an interior surface defining a cavity comprising a first directional retainer portion and a receiving portion, the first directional retainer portion configured to engage a portion of the engaging element of the buckle body and retain the buckle body when the buckle body is forced in a first direction, the receiving portion configured to receive the engaging element of the buckle body and the receiving portion located in a second direction from the first directional retainer portion. In some embodiments, the interior surface further comprises a channel configured to constrain movement of the buckle body in two dimensions and allow the buckle body to move in a third dimension.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims benefit of U.S. Patent App. No. 61/549,173, filed Oct. 19, 2011, entitled “BUCKLE ASSEMBLY AND METHODS OF USE” the entire contents of which are incorporated by reference in their entirety.

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

Not Applicable

REFERENCE TO SEQUENCE LISTING, A TABLE, OR A COMPUTER PROGRAM LISTING COMPACT DISC APPENDIX

Not Applicable

BACKGROUND OF THE INVENTION

This invention relates to releasable buckle assemblies.

In one particular embodiment the buckle assembly comprises a buckle body configured to flex and be releasably retained in a base body.

BRIEF SUMMARY OF THE INVENTION

The following summary is included only to introduce some concepts discussed in the Detailed Description below. This summary is not comprehensive and is not intended to delineate the scope of protectable subject matter.

In one example embodiment of the buckle assembly, the buckle assembly comprises a buckle body having at least one engaging element, a base body having a cavity defining one or more profiles configured to engage a portion of the engaging element of the buckle body and retain the buckle body.

In one example embodiment of the buckle assembly, the buckle assembly comprises a buckle body having at least one engaging element, a base body having a cavity configured to slidably receive a portion of the engaging element of the buckle body and retain the buckle body, the base body further comprising a first directional retainer and a second directional retainer, the first directional retainer configured to engage a first surface of the buckle body and retain the buckle body in a first direction and the second directional retainer configured to engage a second surface of the buckle body and retain the buckle body in a second direction whereby the buckle body is retained in the base body. In some embodiments of the buckle assembly, the engaging element is a resilient finger and in some embodiments, the engaging element is a curved resilient retaining finger.

In one example embodiment of the buckle assembly, the buckle assembly comprises a buckle body having an engaging element, a base body having an interior surface defining a cavity comprising a first directional retainer portion and a receiving portion, the first directional retainer portion configured to engage a portion of the engaging element of the buckle body and retain the buckle body when the buckle body is forced in a first direction, the receiving portion configured to receive the engaging element of the buckle body and the receiving portion located in a second direction from the first directional retainer portion. In some embodiments the engaging element is a resilient finger, a curved resilient finger or a pair of opposing curved resilient fingers.

In some embodiments, the cavity further comprises a second directional retainer portion having a second directional retainer portion profile configured to retain the buckle body in the cavity when the buckle body is forced in the second direction. In some embodiments the buckle body further comprises a pusher portion configured to translate a removing force to the buckle body in the second direction whereby the buckle body may be urged to pass through the second directional retainer portion.

In some embodiments, the buckle body further comprises a stop button, the engaging element comprises a retaining finger, a flex gap defined between the stop button and the engaging element and the flex gap configured to allow the retaining finger to have a plurality of buckle body profiles whereby a first buckle body profile is no less than a first directional retainer portion profile and a second buckle body profile is less than the second directional retainer portion profile. In some embodiment, the plurality of buckle body width profiles further comprises a set buckle body profile less than the second directional retainer portion profile and greater than the first directional retainer portion profile.

In some embodiments, the interior surface of the buckle body further comprises a channel configured to constrain movement of the buckle body in two dimensions and allow the buckle body to move in a third dimension. In some embodiments, the interior surface comprises at least one cavity side wall, a cavity top wall and a cavity bottom wall.

In some embodiments, the buckle assembly further comprises a strap coupler comprising a strap coupler opening configured to receive a strap, the strap coupler further comprising a strap engaging element configured to frictionally engage the strap whereby the strap is retained in the strap coupler. In some embodiments, the strap further comprises at least one strap protrusion and the strap engaging element is an opening whereby the strap engaging element frictionally engages the at least one strap protrusion to retain the strap in the strap coupler.

In one example embodiment, a buckle assembly is provided comprising a buckle body comprising at least one engaging element, a base body comprising an interior surface defining a cavity and at least one base channel, the base body further comprising a receiving portion and a first directional retainer portion, the receiving portion defining a receiving portion profile configured to receive the buckle body into the at least one base channel, the first directional retainer portion defining a first directional retainer portion profile configured to engage the buckle body whereby the buckle body is retained in the cavity when the buckle body is forced in a first direction of a first dimension, the at least one channel defining a channel profile configured to engage the buckle body in a second and third dimension whereby the buckle body is retained in the cavity in the second and the third dimension and the receiving portion located in a second direction from the first directional retainer portion.

In one example embodiment, buckle assembly for fastening a strap to an article is provided comprising a buckle body comprising a means for engaging a base body, a base body comprising an interior surface defining a cavity comprising a first directional retainer portion and a receiving portion, the first directional retainer portion comprising a means for engaging the buckle body and retain the buckle body when the buckle body is forced in a first direction from a set configuration, the base body further comprising a means to receive the buckle body, the means to receive the buckle body located in a second direction from the first directional retainer portion, the cavity further comprising a means to retain the buckle body in the cavity when the buckle body is forced in the second direction, the buckle body further comprising a means to flex into a plurality of buckle body profiles whereby a buckle body retaining profile is no greater than the means for engaging the buckle body and retains the buckle body when the buckle body is forced in the first direction and a buckle body receiving profile is less than the means to receive the buckle body and whereby the plurality of buckle body width profiles further comprises a buckle body set profile greater than the means for engaging the buckle body and retains the buckle body when the buckle body is forced in a first direction and buckle body set profile greater than the means to retain the buckle body in the cavity when the buckle body is forced in the second direction whereby the buckle body set profile retains the buckle body in the cavity of the base body.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

In order that the manner in which the above-recited and other advantages and features of the invention are 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:

FIG. 1A shows a top perspective view of one embodiment of the buckle assembly with the buckle body retained in the base body;

FIG. 1B illustrates the multiple dimension of forces and movement of assembly elements of FIG. 1A;

FIG. 2A illustrates a top perspective view of one embodiment of the buckle body;

FIG. 2B illustrates a top view of one embodiment of the buckle body;

FIG. 3A illustrates a top view of one embodiment of the buckle body and the base body;

FIG. 3B illustrates both a top view and rear profile view of one embodiment of the buckle body highlighting example buckle body profiles;

FIG. 3C illustrates a rear view of one embodiment of the base body;

FIG. 3D illustrates a rear view of one embodiment of the base body;

FIG. 4A illustrates a top perspective view of one embodiment of the buckle assembly with multiple buckle bodies and multiple base bodies in a set configuration;

FIG. 4B illustrates a top perspective view of one embodiment of the base body;

FIG. 5 illustrates a top perspective view of one embodiment of the buckle assembly with multiple buckle bodies;

FIG. 6 illustrates a perspective view of another example embodiment of the buckle body with a strap;

FIG. 7A illustrates an example embodiment of the buckle body; and

FIG. 7B illustrates a cross-sectional view of an example embodiment of the buckle body.

DETAILED DESCRIPTION OF THE INVENTION

A buckle assembly and methods of use will now be described in detail with reference to the accompanying drawings. It will be appreciated that, while the following description focuses on an assembly that can buckle straps, the systems and methods disclosed herein have wide applicability. For example, the buckle assembly described herein may be readily employed with clothing, footwear, fabric, tool belts, building materials or anywhere where a removable coupling between elements is desired. Notwithstanding the specific example embodiments set forth below, all such variations and modifications that would be envisioned by one of ordinary skill in the art are intended to fall within the scope of this disclosure.

One Embodiment of the Buckle Assembly

In one example embodiment, the buckle assembly generally comprises a buckle body and a base body. The buckle body is configured to couple with an article, such as a strap, and be received and retained within the base body. In embodiments, the buckle body is received in the base body from one direction and it is retained in the base body when the buckle body is forced or pulled in another direction. In some embodiments, the buckle body is also secured in the buckle body when a non-removing force is applied to the buckle body while a removing force may remove the buckle body from the base body.

For illustration purposes and not for limitation, one example embodiment of the buckle assembly is shown in FIG. 1A. In the embodiment of FIG. 1A, the buckle assembly 100 comprises a buckle body 120 and a base body 160. The buckle body 120 comprises at least one engaging element 130. The engaging element 130 is one example embodiment of providing a means for engaging the base body. In the embodiment shown, the buckle body 120 further comprises a strap coupler 150 configured to couple the buckle body 120 to another article or element such as a strap 180. The base body 160 is configured with interior surfaces, such as walls, defining a cavity having a first directional retainer portion and a receiving portion. The first directional retainer portion comprises the portion of the base body at a first directional retainer 164 creating a first directional retainer portion profile across a cross-section of the cavity of the base body. The first directional retainer portion is one example embodiment of a means for engaging the buckle body. The first directional retainer portion is configured to engage a surface of the engaging element 130 of the buckle body 120 and retain the buckle body 120 when the buckle body is forced in a first direction, here direction D3-1. The receiving portion comprises the portion of the base body at a second directional retainer 366 creating a receiving portion profile along a cross-section of the cavity of the base body. The receiving portion is one example embodiment of a means for the base body to receive the buckle body. The receiving portion is configured to receive the engaging element 130 of the buckle body 120 and the receiving portion 166 is located in a second direction, here D3-2, from the first directional retainer portion. Also shown are second directional retainers 166a and a pusher portion 158. FIG. 1B illustrates the different dimensions of the buckle assembly of FIG. 1A in a similar perspective view. D1-1 and D1-2 represent a first dimension of the buckle assembly, generally up and down in relation to the base body. D2-1 and D2-2 represent a second dimension of the buckle assembly, generally perpendicular to the tension provided on the buckle body. D3-1 and D3-2 represent a third dimension generally parallel to the tension provided by a strap on the buckle body.

One embodiment of the buckle body generally comprises at least one engaging element. In the embodiment shown in FIGS. 2A and 2B, the buckle body 220 comprises a pair of opposing resilient fingers as engagement elements 230. The engaging elements 230 can be any portion of the buckle body 220 that can that can be resiliently flexed inward and be urged outward back to a shape near its original unflexed position to engage another surface. The engaging element 230 can be integrated with the buckle body 220 or it can be a separate element coupled in any manner that allows the engaging element to resiliently flex so that they can expand or contract to engage another surface. In the embodiment shown, the engaging element 230 is pair of elongated, opposing curved resilient fingers. For some embodiments, the engagement element is a rounded element with rounded edges. The curved engaging element 230 generally comprises a first engaging portion 232 coupling the engaging element 230 to the rest of the buckle body 220. The first engaging element portion 232 has a first engaging surface 242. The engaging element further has a second engaging element portion 238 with a second engaging surface 248. In this embodiment, the second engaging element portion 238 of the engaging element 230 can flex easier given the distance of this element from the engaging element coupling to the rest of the buckle body 220.

In some embodiments, there may be different engaging elements. For example, the first engaging element may be provided by a separate element, or a separate portion of another element whereby it provides a shape to engage the base body and retain the buckle body in a first direction. The second engaging element may also be the curved resilient retaining finger as described above.

In some embodiments, as in those shown in FIGS. 2A and 2B, the buckle body is configured to flex through a plurality, or range of buckle body profiles by the flexing of the engaging elements 230. As shown in FIG. 2B, the buckle body profile is defined by the width P between the outer surfaces of the engaging elements 230. When the engaging elements 230 are flexed inward, the buckle body profile, as defined by the height of the buckle body and the width between the outer surfaces of the engaging elements, may be made smaller creating a smaller buckle body profile. By applying different forces on the engagement elements, different widths, and different buckle body profiles, may be obtained.

Referring back to the embodiment of FIG. 2A, the buckle body may also have a gap stop element, or a stop button 243. In these embodiments, the stop button may assist in keeping the engaging elements from flexing beyond a certain point. In some embodiments, the stop button may be sized to create a profile larger than the first directional retaining portion such that the buckle body is retained by the first directional retaining portion even if the engaging elements were to break off. In some embodiments, a flex gap 244 may also be defined between the engaging elements 230 and other buckle body portions, such as the stop button 243, and should allow for sufficient flex of the engaging elements. In some embodiments, the flex gap 244 can be configured to prevent a first flex but still allow for a smaller second flex.

Also shown in the embodiment of FIG. 2A, the buckle body 220 may further comprise a means for coupling the buckle body to a strap such as a strap coupler 250. The means for engaging a strap may comprise any methods of coupling a strap to the buckle body 220. For example, and not for limitation, the strap engagement means may comprise a clip, a series of openings, a button, adhesives, loops or any other means to couple the strap to the buckle body. Although it is shown in these figures that the strap coupler 250 may be on one end of the buckle body 220, it is also anticipated that the strap coupler can be on any side of the buckle body such as underneath, on the side of or on top.

In the example embodiment shown in FIG. 2B, the strap engaging means is a strap coupler 250 having a strap coupler opening 252 to receive one end of a strap and removably retain the strap. As shown the strap coupler opening 252 is configured to receive the width, thickness and any protrusions of the strap and the strap engaging element 254 is another opening configured to frictionally engage one or more protrusions of the strap. When a strap is placed through the strap coupler opening 252 and a strap protrusion engages the strap engaging element 254, the strap is retained in the strap engaging element 254 and the strap coupler opening 252.

Suitable example materials for the buckle body include, but are not limited to plastics, polyethylene (PE), polypropylene (PP) and polycarbonate (PC), acetal, nylon, thermoplastics, thermoset materials, resins, metals, any combination of these materials or any combination with other materials that can provide a flexible engaging element and a buckle body to be retained in the base body when forces are applied to the buckle body.

Referring to FIG. 3A, one example embodiment of the base body 360 generally comprises a body having interior surfaces, such as one or more walls, to define a cavity 362 configured to receive and releaseably retain the buckle body 320. This illustration includes three base bodies integrated into one base assembly. Other embodiments of the base body comprise any surface configured to engage the engaging element of the buckle body whereby the buckle body is retained. In this example, the base body 360 comprises an interior surface defining a cavity 362 configured to slidably receive and retain a portion of the buckle body 320. The cavity may be generally defined by a two cavity side walls 370 having a width W between them. The width may be non uniform.

In this embodiment, the base body 360 further comprises a first directional retainer 364 and a second directional retainer 366. The first directional retainer 364 is a separate element or a shaping of the cavity side wall configured to engage a first surface of the buckle body, here a portion of an engaging element, and retain the buckle body in a first direction. The profile of the cavity at the first directional retainer 364 defines the location of the cross-section for the first directional retainer portion profile. The second directional retainer 366 is a separate element or a shaping of the cavity side walls configured to engage a second surface of the buckle body, here a portion of an engaging element, and provide a means to retain the cavity of the buckle body in a second direction whereby the buckle body is retained in the base body 360. The second directional retainer 366 generally defines the location of the cross-section of the second directional retainer portion profile. In some embodiments, as in the one shown, but not in all embodiments, the second directional retainer 366 may define the location of the cross-section for both the second directional retainer portion profile and the receiving portion profile. FIG. 3A illustrates an example of one pair of buckle body and base body where the first direction is D1 and the second direction is D2.

The distance between the cavity side walls 370 of the cavity define the cavity width W. The first directional retainer portion, defined between the first directional retainers 364, similar to compression retaining bumps, define a first directional retainer portion having a first directional retainer portion profile including a constraining cavity width W1. The second direction retainer portion, defined between second directional retainers 366 defines a second directional retainer portion having a second directional retainer portion profile including a constraining cavity width W2. The profiles of the two retainer portions are sized such that a first engaging surface 342 of the buckle body can pass through the width W2 but not the first constraining width W1 and the buckle body 320 is constrained in the first direction D1.

As shown in the illustrations of FIG. 3B, the buckle body is configured to flex through a plurality of buckle body profiles. Illustrated are profiles of one embodiment defined through the width and height of the buckle body. The plurality of buckle body profiles at least comprises a buckle body set profile, a buckle body receiving profile and a buckle body retaining profile. These buckle body profiles correspond to the cross-sectional profiles of the cavity of the base body (see FIGS. C and D). The buckle body receiving profile, here illustrated with example width P1, corresponds to the profile of the second directional retainer portion profile W2 (FIG. 3A) such that the buckle body can pass through the second directional retainer portion. An example of the buckle body set profile, here illustrated with example width P, corresponds to the profile of the buckle body no less than the profile of the second directional retainer portion profile W2 (FIG. 3A) and no less than the profile of the first directional retainer portion profile W1 (FIG. 3A) such that when the buckle body is between the second directional retainer portion and the first directional retainer portion the buckle body is set and retained in the cavity of the base body. The buckle body retaining profile, here illustrated as any of the example widths P, P1 or P2, corresponds to the profile that is larger than the first directional retainer portion profile W1 (FIG. 3A). As can be seen in these examples, the flex gap is configured to allow the buckle body to flex into a buckle body width profile no less than a width of the first retainer portion.

Referring back to FIG. 3A, when used together the first directional retainer portion configured to engage a portion of the engaging element, here the first engaging surface 342, of the buckle body and retain the buckle body when the buckle body is forced in a first direction, the receiving portion configured to receive the engaging element of the buckle body and the receiving portion located in a second direction from the first directional retainer portion. The flexing of the engaging elements allows the buckle body to have a range of buckle body profiles whereby a first buckle body profile is no less than a first directional retainer portion profile and a second buckle body profile is less than the second directional retainer portion profile.

In some embodiments, when the buckle body 320 is inserted in the base body 360, the second engaging surface 348 is biased to engage the second directional retainer 366 at the second constraining width W2 whereby the buckle body 320 is constrained in the second direction of the third dimension.

As shown in FIG. 3A, the interior surface of the cavity 362 may also have a portion comprising a cavity bottom wall or a cavity top wall defining at least one channel 368 having a channel profile configured to constrain movement of the buckle body in two dimensions while allowing the buckle body to slide in a third dimension. As shown, the first retaining portion profile comprises the cross-section of the cavity at the first retaining portion, here 1P, which includes width W1 between the cavity side walls or the first directional retainers 364, the bottom wall of the cavity and the top opening of the cavity. The receiving portion profile comprises the cross-section of the cavity at the second retaining portion, here 2P, which include cavity width W2 between the second directional retainers 366, the cavity bottom wall and the top opening of the cavity.

FIG. 3C illustrates another view of one example embodiment of a channel and a channel profile consistent with the embodiment of FIG. 3A. In this embodiment, the cavity top wall 361, and portions of the cavity bottom wall 363 and the cavity side wall 370 define the channel and the channel profile. In some embodiments, one of the cavity top wall or the cavity bottom wall, here the cavity top wall, is not a continuous wall and has a gap allowing portions of the buckle body, or elements coupled to the buckle body, to pass through as the buckle body is being set in the base body cavity. As shown, the first retaining portion profile comprises the cross-sectional opening of the cavity including the width W1 between the first directional retainers 364, the cavity bottom wall 363 and the top opening of the cavity. The receiving portion profile comprises cross-sectional opening of the cavity at the second directional retainers 366 which includes the cavity width W2 between the second directional retainers 366, the cavity bottom wall 363 and the top opening of the cavity. FIG. 3D illustrates one example embodiment of a channel and a channel profile consistent with the embodiment of FIG. 1A. In this embodiment, the cavity top wall 361 is longer and extends further across the base body cavity creating a width W3 between the cavity top walls.

For this, and for other embodiments, the cavity walls may be shaped to help retain the engaging element. For example, if the engaging elements are rounded, a concave cavity wall shape may help retain the engaging elements.

The flex properties of the engaging element 230 should be sufficient to allow a setting force to be applied to the buckle body 220 relative to the base body and allow it to flex to at least the buckle body receiving profile whereby the buckle body 220 can pass through the second directional retainer portion in the first direction into the base body cavity. The setting force is defined as at least the force necessary to force the engaging elements to flex into the buckle body receiving profile. In some embodiments, the flexing of the engaging elements is provided by cooperating shapes of the base body cavity side walls and the external surface shape of the engaging elements.

The resiliency of the engaging element should be sufficient to allow the engaging elements to be urged into the buckle body set profile and stay in a profile larger than the second directional retainer portion profile when a non-removing force is applied to the buckle body in the second direction. The non-removing force is defined as a force no greater than the force necessary to force the engaging element to flex into the buckle body receiving profile. This resiliency constrains the buckle body in the base body when the non-removing force is applied in the second direction. The resiliency of the engaging element may be influenced by cooperative shapes of the base body cavity side walls and the external surface shape of the engaging elements. The interoperation of the engaging element resiliency and the second directional retainer portion profile provide one embodiment of the means to retain the buckle body in the cavity when the buckle body is forced in the second direction.

The flex properties of the engaging element also allow a removing force to be applied to the buckle body whereby the engaging elements are forced to flex to at least the buckle body receiving profile whereby the buckle body can pass through the second direction retainer portion in the second direction out of the base body cavity. The removing force is defined as at least the force in the second direction necessary to force the engaging elements to flex into the buckle body receiving profile. The removing force may be influenced by cooperative shapes of the base body cavity side walls and the external surface shape of the engaging elements.

In some embodiments, the buckle body may further comprise a pusher portion 258. As shown in FIG. 2A, the pusher portion 258 is an accessible surface or a protruding element configured to translate a force to the buckle body 220 relative to the base body. For example, if a removing force is applied to the pusher portion 258, the resilient engaging element 230 of the buckle body 220 may be urged to pass through a second direction retainer portion and our of the base body. The pusher portion 258 may also be used to receive the setting force. The pusher portion 258 may be a specific element provided to translate a force or it may be any portion of the buckle body providing a surface upon which a force can be exerted and translated to the buckle body 220.

The suitable embodiments of FIGS. 1A and 3A have some differences. One difference between the two examples is in the configuration of the base body cavity and channel. As can be seen in FIG. 1A, channel 168 extends generally along the length of the cavity 162. This configuration allows the buckle body 120 to enter the channel 168 from one end and slide into the channel and into the cavity 162. The cavity configuration of FIGS. 3A and 3C has a shorter channel 368 positioned proximal to the first directional retainer 364. The channel 368 still assists in retaining the buckle body in the first direction D1. However, the buckle body 320 does not have to slide through the entire cavity 362 of the base body as in FIG. 1A. In the FIGS. 3A and 3C embodiment, the first engaging surface 342 of the buckle body 320 only needs to be slid into the channel 368 while the remaining portion of the buckle body 320 can be pushed into the cavity 362, in this embodiment, pushed from the top. When pushed from the top, the top surface of the second directional retainers 366 engage the bottom and outer surface of the engaging elements and force the engaging element to flex into the buckle body receiving profile and allow the buckle body to move into the base body cavity. This flexing may be aided by having the outer surface of the engaging elements being rounded or having the top surface of the second directional retainer being slightly sloped downward towards the bottom wall of the cavity. When in the buckle body set profile, the engagement of the second engaging surface 348 with the second directional retainer 366 keeps the buckle body 320 retained in the second direction D2. In this embodiment, the outside surface of the engaging element that frictionally engages the cavity wall at the second directional retainer 366, is at a height less than the top of the cavity wall. This enables the engaging element to be retained in the cavity of the base body. When used with a strap providing tension on the buckle body, the buckle body 320 is further urged to be retained in the channel and the cavity of the base body 360.

FIG. 4A illustrates another view of an example of a coupled embodiment of the base body and buckle body of FIG. 3A. This embodiment of buckle assembly 400 comprises a strap 480 and a buckle body 420 in a set configuration when the buckle body 420 is set in the cavity of the base body. This embodiment also illustrates a stop button 443, and multiple channels 468. FIG. 4B illustrates one embodiment of the base body 460 showing second directional retainers 466.

Suitable materials for the base body include, but are not limited to those described for the buckle body. In addition, the base body may be made of more rigid materials than the buckle body including any materials that can provide rigidity and strength in the cavity to retain the buckle body when forces are applied.

In another embodiment of the buckle assembly shown in FIG. 5, the buckle assembly 500 further includes a strap 580 capable of being coupled to the strap coupler 550. The means to provide the capability to couple the strap to the buckle body 520 may include any type of mating couplers capable of mating the strap 580 to the buckle body 520. Any type of strap suitable for coupling to the buckle body is suitable. In embodiments for use with orthopedic braces and trainers, a resilient or elastic strap is suitable. In the embodiments shown, silicone rubber, P44 is an example of a suitable strap material. Suitable resilient straps for use the buckle assembly also include those described in co-pending U.S. patent application Ser. No. 13/541,796 filed Jul. 5, 2012, co-pending U.S. patent application Ser. No. 13/188,506 filed Jul. 22, 2011 to Lonnie E. Paulos et al now U.S. Pub. No. 20110275970 published Nov. 10, 2011 and co-pending U.S. patent application Ser. No. 12/993,258, filed Nov. 18, 2010, to Lonnie E. Paulos et al now U.S. Pub. No 20110071451 published Mar. 24, 2011, all of which are herein incorporated by reference in their entirety.

In another embodiment, as shown in FIG. 5, the base body 560 may comprise a base body assembly having a plurality of base body cavities 566. In this embodiment, the directions of the cavities 566 are not aligned. This offset of cavity directions provide additional security for straps coupled to the buckle body 520 such that the straps can provide direct resistance to forces from multiple directions. This offset also provides multiple potential configurations of buckle assemblies with a single base body.

As shown in FIG. 6, the strap 680 may further comprise a means to couple the strap to the strap coupler 650 of the buckle body 620. The means to couple the strap to the buckle body 620 may be any type of mating couplers capable of mating with the strap coupler 650 of the buckle body 620. Suitable mating couplers include but not limited to buttons, snaps, clips, hook and loop fasteners or protrusions that mate with recesses in the strap coupler. As shown in FIG. 6, the means to couple may comprise one or more protrusions 684 on the strap to engage the strap engaging element of the strap coupler 650. As shown, a “one-way” embodiment includes protrusions shaped with a profile having a forward curved edge 686 that allows the protrusion to easily slip past a restriction but a rearward sharper edge 688 that retains the protrusion and therefore retain the strap in the strap engaging element of the strap coupler 650. This configuration allows the strap length to be changed without having to move the position of the buckle body or the base body.

In another example embodiment, as shown in FIG. 7A, the buckle body may comprise a strap coupler 750 and a strap slide 751. In this example, the strap 780 is woven through a strap slide channel 753 extending through the slide, underneath a rounded wedge portion 755 of the strap coupler 750, out from the top of the strap coupler 750 and back through the channel 753 of the strap slide. The channel 753 of the strap slide 751 is configured to frictionally engage the strap 780 when it contains the two sections of the strap 780 as shown. The channel 753 is also configured to allow the strap slide 751 to move back and forth when these two sections of the strap 780 are received. The strap slide 751 is able to slide towards the strap coupler 750 such that the strap 780 is urged to further frictionally engage the surface of the rounded wedge portion 755 of the strap coupler 750. In some embodiments, as shown, the strap slide 751 slides over the strap 780 and the strap coupler 750 further coupling the strap 780 to the buckle body 720. The dimensions of the channel 753 of the strap slide 751 are determined such that the stretching and thinning of an elastic strap 780 when tension is placed on it, still allow sufficient friction to be placed on the strap 780 so that it remains coupled with the buckle body 720. Also shown in FIG. 7A, some embodiments of the strap slide 751 further comprise a slide catch 757. The slide catch 757 is configured to couple with a buckle catch 759. In this embodiment, the slide catch 757 comprises a protruding t-shaped element 757T that mates with buckle catch 759. Buckle catch 759 comprises at least one protruding catch to mate with the protruding t-shaped element 757T when the strap slide 751 is slide over the strap 780 and the rounded wedge portion 755 of the strap coupler 750. FIG. 7B illustrates a cross-section of the embodiment of FIG. 7A. Shown here are the rounded wedge portion 755, the strap 780, the strap slide 751 and a gap defining the strap coupler opening 752 between the edge of the rounded wedge portion 755 and the inside walls of the frame of the strap coupler 750. Also shown is a profile of the channel 753 which includes a bottom section 751B of the strap slide creating an interior convex profile and a top section 751T of the strap slide creating an interior convex profile whereby the profile of the channel 753 is restricted and engages the surface of the strap 780 in the channel 753.

One Embodiment of the Buckle Assembly in Operation

Operation of one embodiment of the buckle assembly generally comprises the steps of inserting the buckle body into the receiving portion of the base body, applying a setting force to the buckle body in a first direction relative to the base body and forcing the buckle body engagement element to engage the first directional retaining portion of the base body and retaining the buckle body in the base body. The setting force applied to the buckle body overcomes the flex of the engaging element and allows the engaging element to pass through the receiving portion profile of the cavity. The setting force is not enough to allow the engaging element to pass through the first directional retaining portion profile of the cavity. The buckle body is also retained in the cavity of the base body in a second direction by the receiving portion profile. When a non-removing force is applied to the base body, the receiving portion profile retains the buckle body in the cavity. The buckle body may also be retained in the cavity by an interior surface defined by a cavity bottom wall, a cavity top wall and a cavity side wall. The interior surface engages the buckle body and retains the buckle body in a first and second dimension. Through the interoperation of elements, the buckle body is retained in the base body in two dimensions through the interior surface walls and the buckle body is retained in the third dimension by the constraining profiles of the first directional retaining portion and the receiving portion of the base body.

As shown in the example embodiment of FIG. 3A, the shaping of the cavity side walls and the outer surface of the engaging elements may provide assistance in the operation of the buckle assembly. As shown in this embodiment, the cavity side walls 370 are curved and generally mate with the curve of the engaging surfaces 348 and 342. This curved shaping allows the first engaging surface 342 to more easily flex inward when forced through the curve of the cavity side walls 370 when the setting force is applied. Similarly, the curved shaping allows the second engaging surface 348 to more easily flex inward when a removing force is applied to the buckle body in the second direction flexing the engaging element inward and allowing the buckle body to pass through the receiving portion. Similarly, the shaping of the second directional retainer 366 may provide assistance in the operation of the buckle assembly.

For the base body embodiments illustrated in FIGS. 3A, 3C and 4A, the operation can also be performed in an additional manner. In these embodiments, the circular buckle body may “snap” into the cavity where the retaining fingers of the buckle body can be in an unflexed, here non-compressed, position. This method of receiving the buckle body takes advantage of the top outside surface (366A in FIG. 3C) on the second directional retainer 366 of FIG. 3C as described above. To set the buckle body in the base body, the buckle body is placed in the cavity of the base body from the top of the base body. Since the top of the cavity channel may slightly obstruct the cavity, the portion of the buckle body with the first engaging surface is placed in the cavity slightly behind the cavity channel and then is urged into the cavity channel. The second engaging surface is then snapped into the cavity by pressing downward on the buckle body. In embodiments where the buckle body profile is larger than the cavity profile, the engaging elements may be flexed inward by pressing on the buckle body which forces the second directional retainers to flex the engaging element inward. For some embodiments where the second engaging surface of the buckle body may not fit into the cavity until the first engaging is urged further into the channel cavity, the engaging elements may be configured to flex in another dimension such as in a direction up or down from the rest of the buckle body. In these embodiments, the engaging second engaging surface portion of the engaging element may flex in more than one dimension until the first engaging surface is moved forward and then the second engaging surface may be forced into the cavity of the base body. In these embodiments, the cavity channel, or retaining cover area, retains the buckle body in a fixed position. The open width of the cavity in front of the buckle body is narrower than the profile of the buckle body and therefore retains the buckle body. The buckle body is further retained by the cavity channel or retaining cover area. The first directional retainers, or compression stops, do not allow the buckle to move directionally in the cavity (D1 of FIG. 3A). If the buckle body is pushed in a second direction (for example D2 of FIG. 3A), the engaging elements are compressed and the buckle body moves in the second direction allowing the first engaging surface to move out from under the channel or retaining cover area releasing buckle body from the cavity when pulled outward.

In embodiment of the buckle body similar to those illustrated in FIG. 6, the coupling of the strap 680 to the strap coupler 650 may be done by inserting one end of the strap 680 through the strap coupler opening 652 until one of the protrusions 684 engage the walls defining the strap engaging element 654. The strap 680 may be further pulled through the strap coupler opening 652, forcing one protrusion 684 out of the strap engaging element 654 until another protrusion 684 is engaged with the strap engaging element 654. Adjustment can be made to further tighten the strap by pulling it further through the strap coupler opening 652 or the strap may be loosened by pulling the strap 680 out of the strap coupler opening 652.

In embodiments similar to those illustrated in FIGS. 7A and 7B, the coupling of the strap 780 to the strap coupler 750 may be done by inserting a first end of the strap 780 into the channel 753 of the strap slide 751, weaving that end through the strap coupler opening 752 and back through the channel 753 of the strap slide 751. With the strap loose in the strap slide 751, the first end of the strap is pulled until it is properly tensioned with the buckle body 720. Holding onto the strap and the first end of the strap, the strap slide 751 is slide towards the buckle body 720 until the strap slide 751 secures the strap 780 with the strap coupler 750 and the buckle body 720. The strap 780 may be disengaged by pulling the strap slide 751 back away from the strap coupler 750 and the buckle body 720. In some embodiments, the strap slide 751 may be further secured to the buckle body 720 by having a moving the strap slide 751 forward enough for the slide catch 757 to mate with the buckle catch 759. To disengage embodiments with a slide catch 757 and a buckle catch 759, the strap slide 751 can be moved forward enough to disengage the two catches or the strap slide 751 may be twisted until the two catches disengage. Then the strap slide 751 may be slide away from the buckle body 720 and the strap 780 can be taken out of the strap slide 751. In these embodiments, the strap 780 may be further pulled through the strap coupler opening 752 and the channel 753 to adjust tension on the strap 780.

In embodiments, the setting force can be applied without needing complex manipulation through methods such as putting a force on a coupled strap or pulling on the buckle body or having to flex the engaging element with fingers. When using Silicone Rubber, the tension of the strap may pull the buckle body into the cavity of the buckle body.

Operationally, embodiments of the buckle assembly can also include removing the buckle body from the base body by applying a removal force to the buckle body relative to the base body and forcing the buckle body through the receiving portion and out of the cavity of the base body. The removal force is enough to flex the engaging element of the buckle body inward so that it passes through the second directional retainer and the receiving portion profile of the base body. In some embodiments, the removal force removes the engaging element of the buckle body from the restrainment of the second directional retainer allowing the buckle body to be removed from the cavity.

In some embodiments, the buckle assembly may be used with an orthotic brace to couple or otherwise connect brace elements to each other such as coupling a strap to a brace. Suitable braces which may be utilized with embodiments of the disclosed brace assembly include, but are not limited to those braces described in co-pending U.S. patent application Ser. No. 13/541,796 filed Jul. 5, 2012, co-pending U.S. patent application Ser. No. 13/188,506 filed Jul. 22, 2011 now U.S. Pub. No. 20110275970 and co-pending U.S. patent application Ser. No. 12/993,258 filed Nov. 18, 2010 now U.S. Pub. No 20110071451, the entire contents of all are herein incorporated by reference in their entirety. For some embodiments used with an orthotic brace, the configuration and operation of the buckle assembly benefits users in that the buckle body and base body may be coupled with minimal manual dexterity. The buckle body may be received into the base body by overlapping the buckle body over the base body and slipping the engaging elements into the receiving portion of the base body. Once received, the coupling is secure. To remove the buckle body, it may be disengaged from the base body by providing a removing force on the pusher portion and pushing the buckle body out of the base body. The removal force may also be applied without complex hand manipulation. For example, the removal force can be applied by a thumb or other finger or it may be provided by forcing other element of the buckle body or strap. Additionally, in embodiments that include appropriate strap couplers and straps, adjustment of the orthotic brace can be done with minimal adjustments. For example and not for limitation, when a strap and strap coupler as those illustrated in FIG. 6 are used, the strap length may be adjusted without having to alter the position of the buckle body in the base body. Furthermore, in embodiment with orthotic braces, the buckle assembly may be made with non-metallic materials to comply with sports regulations and the profile of the buckle assembly may be minimized to reduce the buckle assembly's interference with movement of the person wearing the brace.

Although this invention has been described in the above forms with a certain degree of particularity, it is understood that the foregoing is considered as illustrative only of the principles of the invention. Further, since numerous modifications and changes will readily occur to those skilled in the art, it is not desired to limit the invention to the exact construction and operation shown and described, and accordingly, all suitable modifications and equivalents may be resorted to, falling within the scope of the invention which is defined in the claims and their equivalents.

Claims

1. A buckle assembly comprising:

a buckle body having an engaging element;

a base body having an interior surface defining a cavity comprising a first directional retainer portion and a receiving portion;

the first directional retainer portion configured to engage a portion of the engaging element of the buckle body and retain the buckle body when the buckle body is forced in a first direction;

the receiving portion configured to receive the engaging element of the buckle body; and

the receiving portion located in a second direction from the first directional retainer portion.

2. The buckle assembly of claim 1 wherein the engaging element is a resilient finger.

3. The buckle assembly of claim 1 wherein the engaging element is a curved resilient finger.

4. The buckle assembly of claim 1 wherein and in some embodiments, the engaging element is a pair of opposing curved resilient fingers.

5. The buckle assembly of claim 1 wherein the cavity further comprises a second directional retainer portion having a second directional retainer portion profile configured to retain the buckle body in the cavity when the buckle body is forced in the second direction.

6. The buckle assembly of claim 5 wherein:

the buckle body further comprises a pusher portion configured to translate a removing force to the buckle body in the second direction whereby the buckle body may be urged to pass through the second directional retainer portion.

7. The buckle assembly of claim 1 wherein:

the buckle body further comprises a stop button;

the engaging element comprises a retaining finger;

a flex gap being defined between the stop button and the engaging element;

the flex gap configured to allow the retaining finger to flex into a buckle body profile no less than a first retainer portion profile.

8. The buckle assembly of claim 5 wherein:

the buckle body further comprises a stop button;

the engaging element comprises a retaining finger;

a flex gap being defined between the stop button and the engaging element;

the flex gap configured to allow the retaining finger to have a plurality of buckle body profiles whereby a first buckle body profile is no less than a first directional retainer portion profile and a second buckle body profile is less than the second directional retainer portion profile.

9. The buckle assembly of claim 8 wherein the plurality of buckle body width profiles further comprises a buckle body set profile less than the second directional retainer portion profile and greater than the first directional retainer portion profile.

10. The buckle assembly of claim 1 wherein the interior surface further comprises a channel configured to constrain movement of the buckle body in two dimensions and allow the buckle body to move in a third dimension.

11. The buckle assembly of claim 10 wherein the interior surface comprises at least one cavity side wall, a cavity top wall and a cavity bottom wall.

12. The buckle assembly of claim 1 further comprising:

a strap coupler comprising a strap coupler opening configured to receive a strap; and

the strap coupler further comprising a strap engaging element configured to frictionally engage the strap whereby the strap is retained in the strap coupler.

13. The buckle assembly of claim 12 wherein the strap further comprises at least one strap protrusion and the strap engaging element is an opening whereby the strap engaging element frictionally engages the at least one strap protrusion to retain the strap in the strap coupler.

14. A buckle assembly comprising:

a buckle body comprising at least one engaging element;

a base body comprising an interior surface defining a cavity and at least one channel;

the base body further comprising a receiving portion and a first directional retainer portion;

the receiving portion defining a receiving portion profile configured to receive the buckle body into the at least one channel;

the first directional retainer portion defining a first directional retainer portion profile configured to engage the buckle body whereby the buckle body is retained in the cavity when the buckle body is forced in a first direction of a first dimension;

the at least one channel defining a channel profile configured to engage the buckle body in a second and a third dimension whereby the buckle body is retained in the cavity in the second and the third dimension; and

the receiving portion located in a second direction from the first directional retainer portion.

15. The buckle assembly of claim 14 wherein:

the buckle body further comprises a stop button;

the at least one engaging element comprises a pair of opposing resilient fingers;

a flex gap being defined between the stop button and the resilient fingers; and

the flex gap allowing the pair of opposing resilient fingers to flex and define a plurality of buckle body profiles; and

the plurality of buckle body profiles comprising a buckle body retaining profile no less than the first directional retainer portion profile and a buckle body receiving profile less than the receiving portion profile.

16. The buckle assembly of claim 15 wherein:

the receiving portion further comprises a second directional retainer portion;

the receiving portion profile comprises a second directional retainer portion profile; and

the plurality of buckle body profiles further comprises a buckle body set profile no less than the first directional retainer portion profile and greater than the second directional retainer portion profile whereby the at least one engaging element engages the second directional retainer portion and the buckle body is retained in the cavity when the buckle body is forced in the second direction.

17. The buckle assembly of claim 16 wherein:

the buckle body further comprises a pusher portion configured to receive a removing force in the second direction; and

the at least one channel comprising a side wall configured to engage the at least one engaging element and flex the buckle body into the buckle body receiving profile when moved in the second direction whereby the buckle body is moved through the receiving portion profile and out of the cavity of the base body by the removing force.

18. A buckle assembly for fastening a strap to an article, the buckle assembly comprising:

a buckle body comprising a means for engaging a base body;

a base body comprising an interior surface defining a cavity comprising a first directional retainer portion and a receiving portion;

the first directional retainer portion comprising a means for engaging the buckle body and retain the buckle body when the buckle body is forced in a first direction from a set configuration;

the base body further comprising a means to receive the buckle body;

the means to receive the buckle body located in a second direction from the first directional retainer portion;

the cavity further comprising a means to retain the buckle body in the cavity when the buckle body is forced in the second direction;

the buckle body further comprising a means to flex into a plurality of buckle body profiles whereby a buckle body retaining profile is no greater than the means for engaging the buckle body and retains the buckle body when the buckle body is forced in the first direction and a buckle body receiving profile is less than the means to receive the buckle body; and

whereby the plurality of buckle body width profiles further comprises a buckle body set profile greater than the means for engaging the buckle body and retains the buckle body when the buckle body is forced in a first direction and greater than the means to retain the buckle body in the cavity when the buckle body is forced in the second direction whereby the buckle body set profile retains the buckle body in the cavity of the base body.

19. The buckle assembly of claim 18 wherein:

the means for engaging the base body comprises an engaging element;

the means for engaging the buckle body comprises the interior surface of the base body defining the first directional retainer portion having a first directional retainer portion profile configured to engage the engaging element;

the means to receive the buckle body comprises a receiving portion of the base body;

the receiving portion having a second directional retainer portion profile;

the means to retain the buckle body in the cavity when the buckle body is forced in the second direction; and

a means to flex into a plurality of buckle body profiles comprises a flex gap defined between a stop button and the engaging element whereby the buckle body retaining profile is no greater than the first directional retainer portion profile, the buckle body receiving profile is less than the second directional retainer portion profile and the buckle body set profile is greater than the first directional retainer portion profile and greater than the second directional retainer portion profile whereby when the buckle body set profile retains the buckle body in the cavity of the base body.