CROSS REFERENCE TO RELATED APPLICATIONS

[0001] This application claims priority to U.S. provisional application 63/363,249 entitled “Re-usable Sleeve for Blevins Buckle” and filed April 20, 2022, the disclosure of which is hereby incorporated by reference in its entirety.

BACKGROUND

[0002] The disclosure is directed to Western saddle and tacking technology, specifically Blevins buckles aka quick change stirrup adjustment buckles.

[0003] In the field of saddle and tacking technology for horse riding, one major saddle type is the Western saddle. The Western saddle is generally larger, heavier, and provides more comfort and stability for long duration riding as compared to other major saddle types.

[0004] Most modem Western saddles use a Blevins buckle to adjust the stirrup height. The use of a Blevins buckle allows a user to conveniently move the stirrup higher (if the rider has shorter legs) or lower (if the rider has longer legs). Specifically, a Blevins buckle is made up of a metal tongue portion which is attached to the end of the fender which includes an elongated strap at the bottom. The tongue portion includes one or more studs. The studs are then inserted into corresponding holes in a stirrup leather, where the stirrup leather includes a series of holes along its length corresponding to the desired height of the stirrup.

[0005] A sleeve then slides over the tongue and stirrup leather to lock the tongue studs into the stirrup leather holes to prevent unbuckling or loosening. The sleeve generally includes an inner metal liner that is covered by a leather covering on three sides and partially on the fourth side. The leather covering is affixed to the metal liner, and prevents abrasion between the metal liner and the saddle strap or other components of the saddle. Blevins buckles are further described in U.S. Patent No. 3,314,121 to E.L. Blevins et al., the disclosure of which is hereby incorporated by reference in its entirety.

[0006] However, the leather covering may wear over time. Under prolonged use, the leather covering on the Blevins buckle sleeve may crack and tear due to exposure, weathering, and fiction. When this happens, the sleeve generally must be entirely replaced in order to ensure that the edges of the metal liner do not cut into the other components of the saddle or injure the horse. Repeated replacement of the sleeve is considered not environmentally friendly, and imposes non-trivial costs.

[0007] Accordingly, there is a need in the art for a re-usable sleeve for use in a Blevins buckle.

SUMMARY

[0008] In one aspect, the present disclosure is directed to a sleeve for a Blevins buckle comprising: a metal inner liner; a cover piece surrounding the metal inner liner on at least three sides; wherein the metal inner liner includes at least one foldable metal tab adjacent to a first lateral side, and at least one foldable metal tab adjacent to a second lateral side opposite the first lateral side; wherein each foldable metal tab is a continuous portion of the metal inner liner, and is configured to fold from an open position to a closed position; wherein the cover piece includes a plurality of tab holes, each of which aligns with a foldable metal tab on the metal inner liner; and wherein the foldable metal tabs reversibly affix the cover piece onto the metal inner liner when the foldable metal tabs are in the closed position.

[0009] In another aspect, the present disclosure is directed to a sleeve for a Blevins buckle comprising: a metal inner liner; a covering layer, disposed substantially around the metal inner liner; wherein the covering layer is reversibly affixed to the metal inner liner by one or more foldable tabs in the metal inner liner.

[0010] In yet another aspect, the present disclosure is directed to a method of manufacturing and re-using a sleeve for a Blevins buckle, the method comprising: tool and die punching a first side of a sleeve metal inner liner; tool and die punching a second side of the sleeve metal inner liner; tool and die punch out a plurality of tabs in the second side; spot welding the first side and the second side together to create the metal inner liner; cut a piece of covering material into a shape to fit the metal inner liner, including cutting a plurality of tab holes, to create a covering piece; affixing the covering piece to the metal inner liner by aligning the plurality of tabs through the plurality of tab holes and then bending the tabs into a closed position to create the sleeve; and removing the covering piece from the metal inner liner by bending the plurality of tabs into an open position.

[0011] Other systems, methods, features, and advantages of the disclosure will be, or will become, apparent to one of ordinary skill in the art upon examination of the following detailed description. It is intended that all such additional systems, methods, features, and advantages be included within this description and this summary, be within the scope of the disclosure, and be protected by the following claims.

BRIEF DESCRIPTION OF THE DRAWINGS

[0012] The invention can be better understood with reference to the following drawings and description. The components in the figures are not necessarily to scale, emphasis instead being placed upon illustrating the principles of the invention. Moreover, in the figures, like reference numerals designate corresponding parts throughout the different views.

[0013] FIG. 1 is a prior art sleeve for a Blevins buckle, aka a quick change stirrup adjustment buckle;

[0014] FIG. 2 is a prior art inner metal liner for use in the sleeve of a prior art Blevins buckle;

[0015] FIG. 3 is an isometric view of an inner metal liner for use in a quick change stirrup adjustment buckle in accordance with this disclosure;

[0016] FIG. 4 is a side view of an inner metal liner in accordance with this disclosure;

[0017] FIG. 5 is an outer top view of a sleeve for a Blevins buckle in accordance with this disclosure;

[0018] FIG. 6 is a side view of a sleeve for a Blevins buckle in accordance with this disclosure;

[0019] FIG. 7 is an bottom view of a sleeve for a Blevins buckle in accordance with this disclosure; and

[0020] FIG. 8 is flowchart showing the manufacture and re-use of a sleeve for a Blevins buckle in accordance with this disclosure.

DETAILED DESCRIPTION

[0021] Broadly, this disclosure provides a Blevins buckle for use in a Western saddle that includes a re-usable sleeve. The sleeve may include a covering that is reversibly affixed to a metal inner liner by a plurality of tabs. The tabs are portions of the metal inner liner that fold from an open position to a closed position.

[0022] Generally, a Blevins buckle sleeve includes an inner metal liner, which at its rear is provided with offset portions defining a channel. The width of the sleeve is substantially equal to the length of a tongue on the corresponding portion of the Blevins buckle, and the width of channel is slightly in excess of the width of the tongue. The depth of the channel is about equal to the thickness of the tongue.

[0023] The spacing between the opposite sidewalls of the inner metal liner is about equal to the axial length of the studs on the tongue, which are in turn slightly in excess of the thickness of a stirrup strap. The arrangement is thus such that when the studs are positioned in selected openings in stirrup strap, the sleeve first having been moved upwardly along stirrup strap to permit the proper positioning thereof, and subsequently moved downwardly, the tongue fits snugly in the channel with the ends of the studs abutting against the opposite wall of inner liner thus securely holding the studs against disassociation from their associated openings.

[0024] The frictional grip of the opposed sidewall of the inner metal liner on adjacent confronting sides of the tongue and stirrup strap is sufficient to preclude the sleeve from slipping upwardly on the belt, while the shoulders formed by the juncture of the tongue with the plate positively preclude downward movement of the sleeve beyond its locking position. The exterior side of the inner metal liner is surrounded by a relatively soft leather covering, with the exception of the back of channel, which covering is secured thereto by an attachment mechanism which extends along the rear of the sleeve on opposite sides of the channel. The top edges of the metal liner are cut away, as are the bottom edges, to reduce the possibility of the sharp corners thereof scraping or damaging the saddle or blanket, or components of the saddle.

[0025] FIG. 1 shows a conventional sleeve 100 for use in a Blevins buckle. In this well-known technology, the covering 104 on the sleeve 100 is attached to the inner metal liner by several rivets 120, 122, 124, 126. Namely, first rivet 120 and second rivet 122 are adjacent to first lateral side 108 of outer face of the sleeve 100 - and third rivet 124 and fourth rivet 126 are adjacent to a second lateral side 110 of the outer face of the sleeve 100. Leather 104 may extend from first end 106 around to second end 112. The rivets 120, 122, 124, 126 are a non-reversible attachment mechanism, which cannot be removed or opened by an end user. As a result, the entire sleeve (metal and all) must be discarded when the leather covering 104 wears out. This causes increased expenses, and is not environmentally friendly.

[0026] FIG. 2 shows a well known inner metal liner 202 for use in a conventional Blevins buckle. This inner metal liner 202 includes rivet holes 220, 22, 224, 226 therein. Rivet holes are located on either side of the channel 232. Namely, rivet holes 220 and 220 may be adjacent to first lateral side 208 in area 230, while rivet holes 224 and 226 may be adjacent to second lateral side 210 in area 234. All of rivet holes 220, 222, 224, 226 may located on upper side 214. Upper side 214 may be separated from lower side 216 by side portion 218.

[0027] In contrast, FIG. 3 shows an inner metal liner 302 in accordance with this disclosure. This inner metal liner 302 includes tabs 340, 344, 348, 354 each formed from a portion of the inner metal liner 302 - instead of rivet holes. Namely, this inner metal liner 302 includes first tab 340 and second tab 344 adjacent to first lateral side 308 - and third tab 348 and fourth tab 354 adjacent to second lateral side 310.

[0028] As shown in FIG. 3, the tabs 340, 344, 348, 354 are folded upward in the open position. This leaves a hole 342, 346, 350, 356 where the tab was punched out of the surface. Specifically, first tab 340 may create first hole 342 when in the open position, and second tab 344 may create second hole 346 when in the open position. First hole 342 and second hole 346 may be in surrounding area 330 of top side 314 of metal sleeve 302. Area 330 may be a first recessed area 330 on top side 314. Similarly, third tab 348 may create third hole 350 when in the open position and fourth tab 354 may create fourth hole 356. Third hold 350 and fourth hole 356 may be in surrounding area 334 on top side 314 of metal sleeve 302. Area 334 may be a second recessed area on top side 314. First recessed area 330 and second recessed area 334 may be separated by center raised area 332 that forms the channel as discussed above. [0029] Each tab 340, 344, 348, 354 may cut from the surrounding area 330, 334 on one or more sides but leaving a base connecting area 352, 358 between the tab and the surrounding area. For example, third tab 348 may include base connecting area 352 between the tab 348 and the surrounding area 334 - and fourth tab 354 may include base area 358 between the tab 354 and the surrounding area 334. The base connecting area 352, 358 is where the tab may bend from a close position (not shown in FIG. 3) to the open position as shown. By bending along this area, each tab may reversibly open and close so as to reversibly attach a cover layer to metal inner liner 302.

[0030] Broadly, the tabs can be punch with a tool and die in any shape or number as long as the tabs are sufficient to affix the leather or other covering material to the sleeve in a manner that will prevent the sleeve covering from coming off the sleeve.

[0031] Inner metal liner 302 of FIG. 3 may be a two inch sleeve, having a length 391 of approximately two inches. In other embodiments length 391 may be three inches, or other lengths so as to fit the buckle as may be necessary.

[0032] Generally, the inner metal liner shown in FIG. 3 and throughout this disclosure maybe made of a metal - such that tabs are reversibly foldable, but inner metal liner is nonetheless substantially resistant to deformation so that it does not slip when in use. Exemplary metals that maybe used include stainless steel and aluminum.

[0033] FIG. 4 shows a side view of the inner metal liner 302 in accordance with this disclosure. As shown, the tabs 340, 344, 348, 354 are continuous metal portions of the inner metal liner 302. Tabs 340, 344, 348, 354 in the open position may be angled at an approximately 90 degree angle relative to the flat surface 330, 334 of the inner metal liner to which they are connected. Broadly, tabs 340, 344, 348, 354 in the open position may be angled at any angle that will allow easy attachment of the cover to the inner metal liner.

[0034] FIG. 4 also shows how metal inner linter 302 may be one continuous piece of metal that folds back on itself. Namely, top surface 314, first lateral side 308, and bottom surface 316 may be a continuous single layer - while second lateral side 310 may include inner portion 309 that is continuous with area 334 of top surface 314 and also outer portion 311 that is continuous with bottom side 316. Inner portion 309 and outer portion 311 may welded together along a single seam to form the shaped metal inner liner 302 after the single layer has been folded back on itself.

[0035] Fig. 4 also shows how first recessed area 330 may be adjacent to first lateral side 308, second recessed area 334 may be adjacent to second lateral side 310, and center raised area 332 may be located between them.

[0036] FIG. 5 shows an embodiment of a sleeve 500 for a Blevins buckle in accordance with this disclosure. Sleeve 500 shows how cover piece 504 may surround metal inner liner 502 on at least three sides. Namely, FIG. 5 shows the tabs 540, 550, 560, 570, 580, 590 in the closed position - reversibly affixing the cover piece 504 onto the metal inner liner 502. This sleeve 500 may be a three inch sleeve, having a length 591 of approximately three inches, and may therefore include three tabs on each side instead of the two on each side shown in FIGs. 3 and 4.

[0037] In particular, cover piece 504 may include first end 506 and wrap around metal inner liner 502 to second end 512. Adjacent to first end 506 of cover piece 504, and also adjacent to first side 508 of sleeve 500, cover piece 504 may include a plurality of tab holes 546 that correspond to a tab 540. In this way, each of the tabs 540, 550, 560 may be inserted through a corresponding tab hole in the cover piece in order to reversibly secure cover piece 504 to metal inner liner 502 on first side 508. For example, tab 540 may be inserted through hole 546 in cover piece 504 such that tab 540 down to base connecting area 544 lies on top of cover piece 504. Cover piece 504 may then also have corresponding tab holes on side 510 that correspond to tabs 570, 580, 590.

[0038] When the tabs 540, 550, 560, 570, 580, 590 are folded downward into the closed position, the tabs may reversible secure the leather covering piece 504 onto the inner metal liner. The tabs may be moved from the open position shown in FIGS. 3 and 4 into the closed position shown in FIG. 5 by applying pressure, such as by the use of hand plyers. Namely, the leather covering piece 504 may be received (or created) including a plurality of tab holes 546 therein which line up with the tabs on the inner metal liner. The leather covering piece 504 may be placed onto the inner metal liner 502, and the tabs are each extended through each of the tab holes in the leather cover piece 504. Then, the tabs are folded down into the closed position. As a result, the leather covering piece 504 is secured by reversibly attached to the inner metal liner 502. The leather covering piece may therefore perform its function of protecting the stirrup strap and other components of a saddle from the edges of the inner metal liner, while the inner metal liner may perform its function of reversible securing the stirrups at the desired height by attachment to the tongue portion of the Blevins buckle.

[0039] While cover piece 504 may commonly be made of leather, in other embodiments cover piece 504 may be made of other materials. For example, cover piece 504 may be made of an artificial leather, a polymer based material, a cloth material, or other natural or synthetic materials.

[0040] FIG. 5 also shows how first transition area 531 may be located between first cover piece end 506 and raised center area 532. Similarly, second transition area 533 may be located between second cover piece end 512 and center raised area 532 of top surface 514. In this way, as further shown in FIG. 6, a thickness of cover piece 504 may be accommodated.

[0041] FIG. 6 shows a side view of sleeve 500 that is in accordance with this disclosure. In this view, the closed position of each tab is shown. Namely, in the closed position each of the plurality of tabs is folded to be approximately parallel with the remaining adjacent surface of the inner metal liner 502. The tabs may fold inward towards a center line of the sleeve, so as to create tension on the leather covering piece 602 as it extends around each lateral side 606, 610 of the inner metal liner 502 and across the lower side face 516 of the inner metal liner 502.

[0042] Specifically, covering layer 602 may include first end 603 that is adjacent to center raised area 532 and also towards first lateral side 606. Covering layer 602 may also include second end 613 that is adjacent to center raised area 532 and also towards second lateral side 610. First end 603 and adjacent portion 604 of covering layer 602 sit atop portion 530 of metal inner liner 502 that includes securing tabs (as shown in FIG. 5). Covering layer 602 then wraps around first lateral side of metal inner layer 508, so as to cover inner portion 509 and outer portion 511 of first lateral side 508 of metal inner liner 502. Covering layer 602 then cover bottom side 516 of metal inner liner 502 at portion 608. Next, covering layer 602 wraps back up around second lateral side 510 of metal inner liner 502 at portion 610. Portion 612 of covering layer 602 then sits atop portion 534 of metal inner liner that includes securing tabs (as shown in FIG. 5). Covering layer 602 then terminates at second end 613.

[0043] In this way, portion 604 may be sandwiched between the securing tabs pressing down on upper surface 620 of portion 604 and surface 530 that is adjacent to bottom surface 622 of portion 604. Therefore, the leather covering piece 602 is kept in place by the tabs in the closed position and does not significantly move relative to the inner metal liner 502.

[0044] Additionally, FIG. 6 also shows how height 593 of transition areas 533, 531 may correspond to thickness 693 of covering layer 602. In this way, the sleeve 500 may have a raised area 532 that forms a channel having a depth 593 that is about equal to the thickness of the tongue of the Blevins buckle, as discussed above.

[0045] FIG. 7 shows the inner side face 608 of the sleeve 500 in accordance with this disclosure. The inner side face 608 lies adjacent to the stirrup strap, or other components of the saddle. Therefore, the leather covering piece 602 may present a continuous uninterrupted smooth face 608 on the inner side face from first lateral side 606 to second lateral side 610 - in order to reduce friction and avoid any potential snags.

[0046] Finally, this disclosure also provides a method of manufacturing and re-using a sleeve for a Blevins buckle. FIG. 8 shows a flowchart of this method 800. The method 800 may include a first step 802 of tool and die punching a first side of the sleeve inner metal liner. Then the method 800 may include a second step 804 of tool and die punching a second side of the sleeve inner metal liner. In some embodiments of method 800, the first side and the second side are continuous portions of a metal layer that is bent back on itself, as discussed above and variously shown in the other FIGs.

[0047] Next, the method 800 may include a step 806 of tool and die punching out each tab in the second side. This step 806 may include tool and die punching one group of side adjacent to one lateral side at a time. This step 806 may include punching each tab from the metal inner liner on one or more sides, leaving a base connecting area between each tab and a respective surrounding area of the metal inner liner and further leaving a hole in the metal inner liner where the tab was punched out of when the tab is bent into the open position.

[0048] Then, in step 808 the two sides of the inner metal liner may be spot wielded together to form the inner metal liner. In some embodiments where the first side and the second side are continuous portions of a metal layer that is bent back on itself, the step 808 of spot welding the first side and the second side together may comprise spot welding a single seam.

[0049] Next, the method 800 of FIG. 8 may include a step 810 cutting a piece of covering material, such as leather, into a shape to fit the metal inner liner. This step 810 may include cutting a plurality of tab holes into the piece of covering material, so as to create a covering piece. Then at step 812 the covering piece may be affixed to the inner metal liner by aligning the plurality of tabs on the inner metal liner with the plurality of tab holes on the covering piece, inserting each of the tabs through each respective tab hole, and then bending each tab into a close position. This creates the finished sleeve for use in the Blevins buckle.

[0050] However, over time the sleeve becomes worn and the covering piece may tear or break as shown at step 814 of method 800. At that time, the worn covering piece may be removed from the inner metal liner at step 816 by bending the plurality of tabs back into the open position. As a result, a new covering piece may be produced by repeating step 810, or otherwise received, and then again affixed to the inner metal liner by repeating step 812. Thus, in some embodiments of method 800 the steps of 810, 812, 814, and 816 may be repeated multiple times. In particular, the step 816 may be repeated each time the covering layer gets worn, and then step 812 of affixing a new covering layer may be repeated to replace the old covering layer again and again.

[0051] Thus, the metal liner piece may by re-used - thereby allowing environmentally friendly re-use instead of disposal, and allow for cost savings by obviating the need to buy an entirely new sleeve.

[0052] This environmental impact of the re-usable sleeve may be substantial over time, helping to minimize both the cost of the saddle and also minimize the carbon impact by avoiding the repeated manufacture of sleeves that are not reusable.

[0053] While various embodiments of the disclosure have been described, the description is intended to be exemplary, rather than limiting and it will be apparent to those of ordinary skill in the art that many more embodiments and implementations are possible that are within the scope of the disclosure. Accordingly, the disclosure is not to be restricted except in light of the attached claims and their equivalents. Also, various modifications and changes may be made within the scope of the attached claims.