Accidents involving items being dropped from a height at construction sites are common, Often, the dropped item is a tool thai was being carried by a worker. Potential risks to a company using a tool that is dropped include sickness absences, risk of litigation, as well as damage to property, processing equipment or the tool itself. Not only are they hazards, but falling tools can also reduce productivity by time lost in retrieving the dropped tool.

It is known to tie tools to a work belt in order to try to reduce this risk, in some cases using spare pieces of string or wire. This is obviously unsatisfactory and unsecure. A better known solution to the problem is to provide a dedicated lanyard that includes clips at its ends: one for clipping onto a belt or the like, and another to fasten the tool to the lanyard. However, if the lanyard is too short then it can limit the reach of the took On the other hand, if the lanyard is too !ong then it can get in the way or become tangled and be a safety hazard.

Devices with a retractable lanyard have also been produced. However, these are based around a bias that constantly pulls on the cord, causing fatigue in the worker's arms, further, if the tool is dropped then the resulting force is greater than that exerted by the biasing means of the device, meaning thai the tool can still fall in a dangerous manner, causing the device to fail safety tests. The known retractable devices are also normally fixed in position to a belt, meaning that in some circumstances the cord is inconveniently located and can make using the tool awkward.

Embodiments of the present invention are intended to address at least some of the abovementioned problems.

According to a first aspect of the present invention there is provided a too! safety device including:

an elongate flexible member;

a connecting device configured, in use, to releasably connect a tool to the elongate flexible member;

a body from which the elongate flexible member can be extended and into which the elongate flexible member can be at least partially retracted;

a mounting member for mounting the body, In use, on a belt or harness, and

a rotating arrangement for allowing the body to rotate relative to the mounting member, CHARACTERISED IN THAT a rotatable member around which the flexible member can be wound and unwound in use includes a helical channel in which a portion of the flexible member can be received in use,

The safety device may further include a releasabfe locking arrangement for preventing the elongate flexible member from being extended or retracted until the locking arrangement is released.

The safety device can include a rotatable member around which the flexible member can be wound and unwound (when the locking arrangement is released). The safety device can include a biasing device, such as a tension spring, that, in use, biases the rotatable member to rotate in a direction that retracts the flexible member (when the locking arrangement is released). The biasing device may be connected to a spindle component that passes through the rotatable member. The biasing device may also be connected to the rotatable member. The spindle and/or the rotatable member may include a slot in which part of the biasing device is connected.

The locking arrangement: can include a formation that directly or indirectly engages with a corresponding formation on the rotatable member, thereby preventing the rotatable member from rotating until the formation is disengaged. The locking arrangement can include an activation portion a pivotable main portion, with the formation being located on the main portion remote from the activation portion. The formation may comprise a protrusion and the corresponding formation on the rotatable member may comprise a recess or slot. The rotatable member may he generally cylindrical in shape and the corresponding formation may be located on an end surface of the rotatable member. The rotatable member may include a plurality of said corresponding formations, the corresponding formations being arranged at spaced-apart intervals on the end surface.

The body includes a channel in which a guide member can be slidably mounted, wherein the guide member travels within the channel as the flexible member is extended or retracted. The guide member can include a formation that can engage with the helical channel of the rotatable member, wherein the guide member travels with respect to the helical channel as the flexible member is extended or refracted. The guide member can prevent rotation of the rotatable member to prevent further extension of the flexible member when a maximum length of the flexible member has been extended from the body.

According to a further aspect of the present invention there is provided a tool safety device including or comprising; an elongate flexible member;

a connecting device configured, in use, to releasably connect a tool to the elongate flexible member;

a body from which the elongate flexible member can be extended and into which the elongate flexible member can be at least partially retracted;

a mounting member for mounting the body, in use, on a belt or harness, and

a releasable locking arrangement for preventing the elongate flexible member from being extended or retracted until the locking arrangement is released.

.According to another aspect of the present invention there is provided a kit including a safety device substantially as described herein and a tool and/or a belt/harness.

Whilst the invention has been described above, it extends to any inventive combination of features set out above or in the following description. Although illustrative embodiments of the invention are described in detail herein with reference to the accompanying drawings, it is to be understood thai the invention is not limited to these precise embodiments. As such, many modifications and variations will be apparent to practitioners skilled in the art. Furthermore, it is contemplated that a particular feature described either individually or as part of an embodiment can be combined with other individually described features, or parts of other embodiments, even if the other features and embodiments make no mention of the particular feature, Thus, the invention extends to such specific combinations not already described, The invention may be performed in various ways, and, by way of example only, embodiments thereof will now be described, reference being made to the accompanying drawings in which:

Figures 1A, I B and 1C are isometric, front and side views, respectively, of an embodiment of the tool safety device;

Figures 2A and 2B are schematic front and rear views, respectively, of a main body component of the device;

Figure 2C is an isometric view of the main body component:;

Figure 2D is a sectional end view of the main body;

Figure 2E is a sectional side view of the main body component;

Figures 3A and 3B are schematic inner and outer surface views, respectively, of a back plate component of the device;

Figure 3C is a sectional side view of the back plate component;

Figures 4A and 4B are front and sectional side views, respectively, of a belt-attaching plate component of the device;

Figure 5 is an exploded diagram of the components of the device;

Figures 8A and 6B are isometric and sectional side views, respectiveiy, of a release button component of the device;

Figures 7A, 78 and 7C are front, bottom and sectional side views, respectively, of a lock plate component of the device;

Figures 8A and BE3 are isometric views of first and second portions, respectively, of a block assembly component of the device;

Figure 8C is a side view, of Figure 86;

Figures 9A and 98 are front and rear views, respectively, of a drum component of the device;

Figures 9C and 9D are sectional views through lines Q~Q and B ^» B, respectively, of Figure 9A;

Figures 10A and 10B are plan and sectional side views, respectively, of a locking nut component of the device, and

Figures 11A and 11B are isometric and sectional side views, respectively, of a spindle component of the device- Referring to Figures 1A to 1C, an example tool safety device 100 is shown. The device includes a main body casing 102 having a generally square rear portion 103A and a generally cylindrical front portion 103B. The main body casing is further detailed in Figures 2A ·--· 2E.

The safety device 100 further includes a back plate 104 thai is generally square shaped and is dimensioned to correspond to the rear portion 103A of the main body. The back plate is further detailed in Figures 3A - 3C. The main body casing and back plate are fixed together by carbon steel cap head screws 106, which are fitted through apertures in the four corners of the components.

In the example, the main body casing and the back plate are formed of Polyamide (PA) 8 with 30% glass fibre (GF) material; however, it will foe appreciated that other suitable, high-impact resistant materials) could be used, It will also be understood that the design and dimensions of all the components of the safety device described are exemplary only and many variations are possible. Further, it should be understood thai it is possible to form embodiments with different sets of components and in some cases, the components described herein may be formed of more than one piece, or may be combined. The external surfaee(s) of the safely device may have branding or other vvords/symbois formed/printed on it during manufacture or afterwards.

As can be seen in Figures 3A and 3B, the back plate 104 includes a central hexagonal aperture 302, The rear surface of the back plate includes a generally central cylindrical protrusion 108, being the end of a spindle 518 {see Figure 5 below) used to rotatabiy mount a belt fixing plate 110 on the back plate 104. This fixing plate 110 is generally rectangular in outline and includes T~ shaped slots 112A, 112B at either side. The T-shaped slots are mirror images of each oilier, with rounded edges. In the example the fixing plate 110 is formed of rniid steel and is detailed in Figures 4A and 48. it includes a circular central aperture 402, In use, the plate 110 is used to attach the safety device 100 to a worker's belt (not shown). The belt is siidably fitted into the T-shaped slots, although it will be understood that other ways of attaching the belt to the safety device are possible, e.g. apertures or clips. In other cases, the safety device may be formed with an integral/non -removable belt or the like. In alternative embodiments, the safety device may be modified in order to be connected to a worker's harness. In some cases this may be achieved by angling the side portions of the back plate.

The front surface of the main body casing 102 includes a raised area 114 and has a generally central aperture 118 in its front surface. A circular locking button 118 partially protrudes through this aperture. In the example, the locking button can be of a colour that contrasts with other components of the safety device 100 (e.g. red button in a black casing) and it will be understood thai other components could have different colours too. In use, the locking button is used to control whether the flexible member 120 can be extended from/retracted into the main body casing 102, as will be discussed below, In the example, the flexible member is formed of polyestercord sp 30, pre-stretched, hardened and high-visibility material and has a length of 1.2 m; however, it will be understood that variations to the materiai(s) and dimensions are possible. For example, it may be formed from a plurality of strands (of matehai(s) such as galvanised steel, Mild steel, polymers, Keviar, copper or stainless steel, for instance), at least some of which may be woven/twisted together for strength.

Referring to the exploded diagram of Figure 5, it can be seen that the locking button 118 is part of a button component 502 thai is detailed in Figures 6A and 88. The button component 502 (formed of PA8 30% GF in the example) has a generally elongate body 802 with a cylindrical pivot 804 that extends perpendicularly across the main axis of the body, at its middle. The thickness of this body tapers from this middle portion towards its ends. The button 118 protrudes from the front surface at one end of the body in a first direction whilst a paw! 806 extends from the rear surface at the opposite end of the body.

The button component 502 is fitted inside the raised area 114 of the main body casing 102 so that the button 118 fits through the centra! aperture 118 and the upper end of the elongate body 602 is located above it within the raised area. As shown in Figure 5, a look plate 504 (formed of mild steel in the example), fixed by three (IV13 x 5 mm black oxide cap head) screws 508 to the inside of the main body 102, is used to hold the button component 502 in place. The lock plate 504 has a curved lower end and a flat upper end. The lock plate 504 is further detailed In Figures ?A ~ 7C. As can be seen, the upper end portion 702 of the lock plate is dog-legged away from surface that faces the button component. This upper end portion 702 includes a rectangular indentation/thinned portion 704, which part of the button component 502 can contact in use.

The bottom surface of the main body casing 102 has an aperture 207 (shown in Figures 2B, 2C and 2D) through which a lower part of a block assembly/guide 508 extends. This block assembly/guide 508 is detailed in Figures 8A _--- · 8C. The assembly comprises two halves 802A, 802B (formed of PA8 30GF in the example) and are generally mirror images of each other. They each include a curved channel 804A, 804B that runs from its upper end to its bottom end, and can be fixed together by means of pins, screws, or the like, fitted through apertures 808. Each half includes a pair of opposed side ledges 808A, 81 OA, 808B, 810B. These are formed to slidahly fit info the elongate horizontal slot 203 (shown in Figure 2B) in the main body casing 102. The block 802B also has an upstanding tenon 812 at the upper end which can locale within a helical channel 902 of the drum component 512 (described below) for guiding the flexible member 120 into the channel 902,

The flexible member 120 is threaded through the channel 804 of the block assembly 508. The external end (and/or adjacent portion) of the flexible member is fitted (e.g. by being tied/fused through apertures or any other suitable connection manner) with a device 122 that can be attached to a hand or power tool (e.g. hammer, axe, screwdriver, power drill, etc). In the example, the tool connecting device is a 13 mm (0.5") trigger snap device, such as ones produced by Sinox Lock Company of New Taipei City, Taiwan, but. it will be understood that other tool connecting means (e.g. other clips (which may swivel), locks or clamps, engaging formations, etc) could be used.

The internal end (and/or adjacent portion) of the flexible member 120 is received by a drum component 512 (formed of PA6 30% GF in the example), which is shown in detail in Figures 9A - 9D. The drum component is generally cylindrical and has a helical channel 902 formed on its curved outer surface, it also includes a bore 904 through its central axis. The front surface of the drum includes a circular formation 906 and four square hole pockets 907A - 907D, arranged at 90° intervals over the front surface. It will he appreciated that the number, design and positioning of the pockets could be varied. Near the "11 'o'clock" position of the circular formation, there is a curved slot 910. The rear surface of the drum includes a ring-shaped indentation 912. The infernal end (and/or adjacent portion) of the flexible member 120 can be fixed to the drum by means of an aluminium ferrule that, is crimped onto it, and the end of the flexible member 120 is then fed through one of the apertures in the drum. The ferruled end is fixed in a square hole pocket 907 of the drum. It will be appreciated that the flexible member can be fixed to the drum in alternative ways.

As will be described below, rotation of the 6rum causes the flexible member to be wound or un-wound into/out of the channel 804. thereby allowing the flexible member to retract into, or extend out of, the main body casing 102. A tension spring 514 (formed of spring steel in the example) is mounted on the front surface of the drum component 512. The outer free end of the spring is fitted into the curved slot 910 of the drum, A threaded fastener/PEM ® nut 513A (formed of steel in the example), a locking nut 5138 (formed of mild steel in the example) and a pan head nut 513C (formed of carbon steel in the example) can also he used to fasten the assembly together. The locking nut 513B is defaiied in Figures 10A and 10B.

A spindle component 516 is used to fix some of the components of the safety device 100 together and also allows the drum component 512 and the belt-mounting plate 110 at least to rotate relative to the main body 102. The spindle is detailed in Figures 11 A and 11B and, in the example, is formed of mild steel. One end includes a cylindrical shank 1102 with an elongate slot 1103 in its curved surface that runs along its length. The spindle further includes a central cylindrical shank 1104, of a diameter greater than shank 1102. The shank 1104 has an axial notch 1105 on lis end surface that is aligned with the slot in the shank 1102. Adjacent the central cylindrical shank there is a hexagonal portion 1106, leading to a first cylindrical end portion 1108 and a second, smaller-diameter end portion 1110.

When assembled, the first end portion 1108 of the spindle 516 is fitted through the circular central aperture 113 of the belt-mounting plate 110 so that the second end portion 1110 protrudes beyond the back surface of the plate. A washer 518 (formed of mild steel in the example) is fitted over the protruding end portion in a manner that allows the belt-mounting plate to rotate freely through 360° (although it will be understood that in alternative embodiments, rotation of the plate may be restricted or controlled). The hexagonal portion 1108 of the spindle 516 is fitted through the hexagonal central aperture 302 of the back plate 104 (the fitting hexagonal shapes prevent the back plate and also the main body 102 from rotating with respect to the spindle). The centra! cylindrical shank 1104 fits into the centra! bore 904 of the drum component 512 and the end cylindrical shank 1102 extends beyond of the front surface of the drum and so can be located in the middle of the coil of the tension spring 514, with the inner end of the tension spring being fixed in the slot 1103 of the shank 1102 and the notch 1105 in the shank 1104. A compression spring 520 is fitted in the recess at the top of the spindle and is retained in place by the release button when the components are assembled.

In use, the user attaches the safety device 100 to a belt or harness using the plate 110. He/she then pulls the flexible member 120 in order to extend it out of the main body 102 and connect it to a fool using the attaching device 122. The block assembly 508 slides within the slot formation 203 of the main body as the flexible member is wound/unwound. At any time, the user can press the button 118 to lock the flexible member at the selected extended length. Pressing the button causes the button member 502 to pivot, which stops the drum 512. from rotating, which also prevents the block assembly 508 from sliding. The pawl 808 of the button member can engage one of the square holes 907 of the drum 512, preventing the drum from winding the flexible member back on until the release button is pressed again, If the device is not locked then the tension spring 514 vviil tend to rotate the drum until a maximum extendable length of the flexible member is fully withdrawn (in alternative embodiments, the tension spring may be configured to tend to retract the f!exible member). The drum may be prevented from rotating further by the block member 508. When the block member has travelled to the end of the helical channel, the tenon 812 on it can prevent the drum from rotating further in that direction.

If the too! connected to the flexible member 120 is accidentally dropped then this can cause a greater than expected force to be exerted on the safety device. The drum 512 rotates until it has fully deployed the flexible member to its maximum length.

The example safety device 100 described herein can have a tensile strength of 260 kg and passes UK drop tests for certifying its use with tools weighing up to 5 kg (Safe Working Load). The weight of the example device is 400 g and it can operate in a temperature range of -30°C to +50°C. The safety devices can be batch tested and be provided with traceable warranties. The rotating plate of the device allows it to conveniently twist and "follow ^" the direction in which the user is moving the attached tool, with less risk of tangling or the user needing to use two hands than conventional lanyards.

The configuration of the tool safety device according to the invention has a number of advantages over conventional retractable lanyard devices where the lanyard itself is wound and unwound onto a drum of sufficient depth and width corresponding to the length of the lanyard in that with such a conventional arrangement it is easily possible for the lanyard to become snagged as it is being wound or unwound, and where such a lanyard is attached at its proximal end to e.g. a heavy tool it will be apparent that in the event of the tool being accidentally dropped from a height the momentum gained as if unwinds itself from the drum can result in failure due to sudden tensionai forces being applied at the drum end of the lanyard. With the present invention the possibility of the flexible member 120 becoming entangled is avoided by winding and unwinding it over the helical drum 512 and fixing that end of the flexible member within the drum so that it exits from it transversely from the major axis of the flexible member as it is being wound and unwound and as it is being guided along the helical grooves by the guide block assembly 508, In addition, it has been found that any debris accumulating on the flexible member 120 after if has been unwound from the drum 612 is automatically removed by the presence of the block assembly 508 when being re-wound onto the drum. The brake mechanism also allows for no accidental return of the flexible member 120 without the release button 118 being pressed, the arrangement also providing for the length of the unwound flexible member 120 to be infinitely variable within the limit of its length, A further advantage of this design is that on assembly, the tension in the spring 518 can be adjusted to provide for e.g. a neutral weight balance for different weighted objects such as tools, whereas with conventional devices the tension is constant and may be too great for use with e.g. lightweight tools, being designed instead to accommodate heavier weights than may be required in practice.