SAFETY SUIT

Abstract

A safety suit including a torso portion and a ring anchor. The torso portion includes a front portion, a back portion and fibers that run vertically through the torso portion. The ring anchor is disposed on the back portion and the fibers are attached to the ring anchor. The fibers extend away from the ring anchor into arm portions and/or leg portions connected to the torso portion.

Description

RELATED APPLICATIONS

This application is a U.S. Utility Application which claims the benefit of U.S. Provisional Application No. 61/234,622, filed Aug. 17, 2009, the entire contents of which are incorporated herein by reference.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to a safety suit. Specifically, the present nvention is for a safety suit designed to capture a worker during a fall.

2. Backgroudn Information

Construction work can be dangerous and often requires working at dangerous heights. When working at dangerous heights, workers often wear a safety harness attached to a safety rope. The safety harness can either wrap around the worker's shoulders and chest or can wrap around the worker's shoulders, chest and groin area. While these types of safety harnesses may hold the worker in the event of a fall, workers usually find the harnesses uncomfortable and restricting. The safety harness can cause chaffing, cuts, or burns and can be uncomfortable in warm weather.

The prior art has been unsuccessful in combining strength and comfort. For example, U.S. Pat. No. 5,366,786 to Connor et al discloses a protective garment with material that comprises three layers of laminate. Specifically, a thermally bonded spunbond web of thermoplastic filaments and a nonwoven fabric laminate comprising an internal layer of meltblown thermoplastic microfibers are sandwiched between two layers of spunbond thermoplastic filaments. However, this garment likely does not provide the strength needed to hold the worker in the event of a fall.

U.S. Patent Application Publication No. 2009/0070916 discloses a protective garment comprising an overlayer, a cover layer and a liner. The liner is made of flexible material such as UHMWPE and is a Jersey knitted fabric.

U.S. Patent Application Publication No. 2008/0060101 illustrates an attempt to provide a suit with high-strength materials. A protective cover for a space suit includes a material that is of a high-strength, lightweight, coated fabric or laminate of films and fabrics. A means for self-healing the materials by sealing small penetrations is also provided. However, it appears unlikely that the protective suit would withstand the forces involved with capturing a worker during a fall.

U.S. Pat. No. 7,047,567 to Allen is exemplary of prior art attempts that have sought to incorporate a harness into a safety suit. A turnout coat and pants with a built-in safety harness are described. Leg straps and upper straps on the coat connect to establish a harness that runs from the thigh to the shoulder, thereby likely confining movement of a wearer.

U.S. Pat. No. 5,960,480 to Neustater et al places a safety harness inside of coveralls. The harness comprises straps that wrap around the torso and run from the upper thigh to the shoulder. The straps of the harness run through inner sleeves disposed on an inner section of the coveralls. While this may prevent entanglement, the straps still squeeze the body and confine movement.

In view of the above, it will be apparent to those skilled in the art from this disclosure that a need exists for a safety suit that is comfortable to wear over a wide range of temperatures and which does not encumber the wearer's movement. This invention addresses this need in the art as well as other needs, which will become apparent to those skilled in the art from this disclosure.

SUMMARY OF THE INVENTION

It is an object of the present invention to provide a safety suit that is comfortable for the worker and provides reliable safety in the event of a fall. It is another object of the present invention to provide a safety suit which may be worn at dangerous elevations without encumbering a wearer or restricting his or her movement.

These and other objects, features, aspects and advantages of the present invention will become apparent to those skilled in the art from the following detailed description, which, taken in conjunction with the annexed drawings, discloses preferred embodiments of the present invention.

BRIEF DESCRIPTION OF THE DRAWINGS

Referring now to the attached drawings which form a part of this original disclosure:

FIG. 1 is a plan view of a front of a safety suit in accordance with an embodiment of the invention;

FIG. 2 is a plan view of a back of the safety suit of FIG. 1;

FIG. 3 is a plan view of a front of a safety suit according in accordance with another embodiment;

FIG. 4 is an alternative embodiment of the safety suit shown in FIG. 3;

FIG. 5 is a cross-section of the safety suit in FIG. 1 taken along line 5-5;

FIG. 6 is a representative, partial cross-section of an alternative embodiment for that shown in FIG. 5; and

FIG. 7 is a representative, partial cross-section of an alternative embodiment for that shown in FIG. 5.

DETAILED DESCRIPTION

Preferred embodiments of the present invention will now be explained with reference to the drawings. It will be apparent to those skilled in the art from this disclosure that the following description of the embodiments of the present invention is provided for illustration only and not for the purpose of limiting the invention as defined by the appended claims and their equivalents.

Referring initially to FIG. 1, an embodiment of a safety suit is illustrated generally at 1. The safety suit 1 has a torso portion 2, a first arm portion 4, a second arm portion 6, a first leg portion 8, and a second leg portion 10. The safety suit 1 is made of woven or non-woven fabric and has small microdiameter fibers of a suitable material, for example, a synthetic material, running through the suit 1 and exiting at the back. The fabric can be woven or non-woven.

Preferably, the safety suit 1 comprises material that is of a high-strength textile, fabric or laminate of films and fabrics. Flexible material with high strength may be selected from the group consisting of cotton, polycotton, steel, glass, polyaramid, wool, polyamide, polyester, polyethylene, including those fibers sold under the name DYNEEMA, for example, UHMWPE, or SPECTRA, and combinations thereof. Yarns of these materials may be formed into fabrics for use in the making of the safety suit 1 using any process known in the textile art (including weaving and/or knitting). The choice of material may depend on the needs of the wearer as will become apparent to one of ordinary skill in the art from this disclosure. Other examples of high strength fibers can be those designated as SB61 and HB51 manufactured by DSM Dyneema Corp. of the Netherlands.

After a fall, if the worker is not quickly retrieved and extracted from a typical safety harness, the blood circulation begins to be cut off at the legs, shoulders or arms from the straps of the harness. The straps of the harness essentially create a tourniquet effect which can cause severe injury or even be fatal. The safety suit 1 of the present invention distributes weight around the body to avoid injury after the fall. The safety suit 1 is configured to be worn as clothing for a daily uniform, for example. The safety suit 1 is preferably configured to be washable and require the same or similar care of standard work clothes.

The various portions 2, 4, 6, 8, 10 of the safety suit 1 can be fixed together using suitable securing means such as stitching, or other mechanical, chemical or physical fastening means. In one embodiment, the stitching can also be made of synthetic fiber. The safety suit 1 has pockets 3 that are integral with the torso portion 2. The pockets 3 have pouches (not shown) secured to an inner surface to fit along the contours of the suit 1.

Referring to FIG. 2, a back portion 14 of the torso portion 2 is illustrated. In this embodiment, the back portion 14 includes a ring anchor 16 which is positioned generally between the shoulder blades of a wearer to maintain the wearer in a generally upright position in the event of a fall. The ring anchor 16 can be a structure that is integral with the material of the safety suit 1. Specifically, the ring anchor 16 can be knitted, woven or stitched into the safety suit 1 such that the ring anchor 16 is securely fastened to the back portion 14 of the torso portion 2. The ring anchor 16 can be made of synthetic fiber as well.

The back portion 14 further has a ring 18 secured to the ring anchor 16. The ring 18 is for connection with a karabiner (not shown), or the like, on a safety rope (not shown) and can be made of various materials, such as steel or alloys that will not break in the event of a fall. The ring 18 can also be made of synthetic fibers, such as UHMWPE. As discussed above, as required by OSHA, the ring anchor 16 and the ring 18 are positioned at an outer surface approximately mid-back between the shoulder blades of the wearer.

Still referring to FIG. 2, the back portion 14 has a zipper 20 running vertically. However, the zipper 20 does not extend to a neck portion 11 of the torso portion 2. Rather, an upper section 15 of the back portion 14 is of a construction that is integral with the front portion 12, shoulder portions and arm portions 4, 6. To wear the safety suit 1, the worker will open the zipper 20 and insert his legs into a corresponding leg portion 8, 10. Next, the worker will insert his arms into a corresponding arm portion 4, 6, place his head through the neck portion 11 and close the zipper 20. This integral upper section 15 provides increased support in the event of a fall. Additional support is provided with straps 21 and buckles 22 on opposing sides of the zipper 20. The straps 21 and buckles 22 connect and cinch the safety suit 1 tight and provide further strength around the zipper 20. To provide further support and secure the safety suit 1 to the worker, stirrups 34 are attached at each end portion of the leg portions 8, 10. In addition, a high-strength webbing 36 is attached at an inner surface along a buttocks portion of the back portion 14, as shown by the cutaway portion at 38 in FIG. 2. The webbing 36 is structured to provide additional support at the user's buttocks since the buttocks portion of the back portion 14 may receive a large portion of the force from the worker's weight when the fall is arrested.

Referring to FIG. 3, an alternative embodiment of the safety suit 1 is shown wherein the front portion 12 has the zipper 20 extending vertically along the torso portion 2. The ring anchor 16, having the ring 18, is disposed on the back portion 14 and is shown in broken/hidden lines.

Referring to FIG. 4, another embodiment of the safety suit 1 is shown wherein the arm portions 4, 6 and leg portions 8, 10 are shortened. This embodiment is a modification of the embodiment in FIG. 3. However, it will be apparent to one of ordinary skill in the art from this disclosure that the arm portions 4, 6 and leg portions 8, 10 can be shortened as a further modification to other embodiments. Since a great deal of construction work is done during the summer months, the short arm and leg portions 4, 6, 8 and 10 advantageously provide a comfortable, as well as cooler and more flexible, garment for the worker in warm weather.

In the embodiments shown, the safety suit 1 can have fibers 24 (preferably synthetic) that run vertically along the length of the safety suit 1. The fibers 24 are high strength fibers made of material described above. The fibers 24 can also be supplemented with carbon nano tubes along their length for additional strength. The fibers 24 can be made into sheets using various methods such as lamination and/or providing a type of backing or lining. These sheets can then be pieced together to form the safety suit 1. The safety suit 1 having fibers 24 that run vertically the length of the safety suit 1 increases the strength of the safety suit 1 and therefore increases the ability to catch the worker in the event of a fall. In one embodiment, a majority of the vertical fibers 24 in the safety suit 1 end at and are securely attached to the ring anchor 16. Thus, a majority of the high-strength fibers are directly connected to the anchor 16, ring 18 and safety rope. Preferably, all of the fibers 24 reach around and/or extend to the back of the safety suit 1 and attach to the ring anchor 16. This advantageously provides a safety suit 1 that is comfortable in that it fits the worker similar to common garments and further provides a strong binding around the worker in the event of a fall. Accordingly, in the event of a fall, a safety rope pulls upwardly on the ring 18 and ring anchor 16. The ring anchor 16, being attached to the high-strength, synthetic, micro fibers 24 pulls on the fibers 24, which are on and around the worker's body, to securely catch the worker and stop the fall.

With specific reference to FIGS. 1 and 5, an embodiment is illustrated wherein a plurality of micro fibers 24, having microdiameters, are disposed in a fabric shell 26 of the safety suit 1. The fabric shell encases the fibers 24 with an inner layer 28 and an outer layer 30 being disposed on opposite sides of the fibers 24. The fibers 24 are pressed along side each other in one or more layers and glued or laminated together. The fibers 24 are secured to at least a portion of the fabric shell 26 to aid in grasping the worker as well as the safety suit 1 in the event of a fall.

Referring back to FIG. 1, a section of the outer layer 30 is removed to expose the fibers beginning at border 32. This removed section serves to illustrate the fibers 24 running vertically through the safety suit 1. The fibers 24 can be disposed between the inner layer 28 and outer layer 30 in a substantially flat, single layer, as shown in FIG. 5. Alternatively, the fibers 24 can be disposed between the inner layer 28 and the outer layer 30 in multiple layers, as illustrated in the embodiment of FIG. 6.

In addition to the foregoing, the safety suit 1 can be provided with a fabric shell 26 having more than two layers as needed for comfort or warmth. The inner or outer layers 28, 30 can also be thickened layers as needed for comfort or warmth. An example of a thick layer is shown in FIG. 7, in which the inner layer 28 includes a coarse yarn that forms an inner knitted surface and a finer yarn that forms a smoother surface. The inner coarse yarn is heavily brushed for a comfortable feel. Furthermore, the inner layer 28 provides bulk that can act as a shock absorber as well as a protective layer during heavy work.

In understanding the scope of the present invention, the term “comprising” and its derivatives, as used herein, are intended to be open ended terms that specify the presence of the stated features, elements, components, and/or groups, but do not exclude the presence of other unstated features, elements, components, and/or groups. The foregoing also applies to words having similar meanings such as the terms, “including”, “having” and their derivatives. The terms of degree such as “substantially”, “about” and “approximate” as used herein mean a reasonable amount of deviation of the modified term such that the end result is not significantly changed. For example, these terms can be construed as including a deviation of at least ±5% of the modified term if this deviation would not negate the meaning of the word it modifies.

While only selected embodiments have been chosen to illustrate the present invention, it will be apparent to those skilled in the art from this disclosure that various changes and modifications can be made herein without departing from the scope of the invention as defined in the appended claims. For example, the size, shape, location or orientation of the various components can be changed as needed and/or desired. Components that are shown directly connected or contacting each other can have intermediate structures disposed between them. The functions of one element can be performed by two, and vice versa. The structures and functions of one embodiment can be adopted in another embodiment. It is not necessary for all advantages to be present in a particular embodiment at the same time. Every feature which is unique from the prior art, alone or in combination with other features, also should be considered a separate description of further inventions by the applicant, including the structural and/or functional concepts embodied by such features. Thus, the foregoing descriptions of the embodiments according to the present invention are provided for illustration only, and not for the purpose of limiting the invention.

Claims

1. A safety suit for arresting a fall, comprising:

a torso portion including a front portion, a back portion and fibers that run vertically through the torso portion; and

a ring anchor disposed on the back portion, the fibers being attached to the ring anchor and extending away from the ring anchor into arm portions and/or leg portions connected to the torso portion.

2. The safety suit of claim 1, wherein the fibers are disposed in laminated sheets.

3. The safety suit of claim 1, further comprising a fabric shell disposed in the torso portion and encasing the fibers.

4. The safety suit of claim 1, wherein the fibers are synthetic.

5. The safety suit of claim 1, wherein the fibers include microfibers with microdiameters.

6. The safety suit of claim 1, wherein the fibers are disposed in a single layer.

7. The safety suit of claim 1, wherein the fibers are disposed in a plurality of layers.

8. The safety suit of claim 1, wherein the fibers include high-strength fibers.

9. The safety suit of claim 8, wherein the high-strength fibers include ultra high molecular weight polyethylene (UHMWPE) fibers.

10. The safety suit of claim 9, wherein the high-strength fibers include carbon nanotubes along the length thereof.

11. The safety suit of claim 1, further comprising a ring attached to the ring anchor and configured for connection to a safety line.

12. The safety suit of claim 1, wherein a plurality of the fibers are one-piece, unitary fibers.

13. The safety suit of claim 1, further comprising a fabric shell having inner and outer layers, wherein the inner layer provides bulk to absorb shock and to act as a protective layer.

14. The safety suit of claim 13, wherein the inner and outer layers are thickened for warmth.

15. The safety suit of claim 13, wherein the inner layer is thicker than the outer layer.

16. The safety suit of claim 15, wherein the inner layer includes coarse yarn.

17. The safety suit of claim 16, wherein the coarse yarn is heavily brushed.

18. The safety suit of claim 1, further comprising stirrups attached to the leg portions.

19. The safety suit of claim 1, wherein the torso portion includes a zipper for securing a worker within and straps and buckles adjacent the zipper to cinch together for added safety.

20. The safety suit of claim 1, wherein the torso portion includes a buttocks portion having a reinforcing, high-strength webbing disposed at an inner surface of the buttocks portion.