U.S. patent application number 11/841872 was filed with the patent office on 2008-03-13 for reel based closure system.
Invention is credited to Gary R. Hammerslag, Mike Mayberry, Mark Soderberg.
Application Number | 20080060167 11/841872 |
Document ID | / |
Family ID | 46329198 |
Filed Date | 2008-03-13 |
United States Patent
Application |
20080060167 |
Kind Code |
A1 |
Hammerslag; Gary R. ; et
al. |
March 13, 2008 |
REEL BASED CLOSURE SYSTEM
Abstract
Disclosed is a closure system used in combination in any of a
variety of applications including clothing, for example as a
footwear lacing system comprising a lace attached to a tightening
mechanism. The lace extends through a series of guide members
positioned along two opposing footwear closure portions. The lace
and guides preferably have low friction surfaces to facilitate
sliding of the lace along the guide members so that the lace evenly
distributes tension across the footwear member. The tightening
mechanism allows incremental adjustment of the tension of the lace.
The closure system allows a user to quickly loosen the lace and
inhibits unintentional and/or accidental loosing of the lace.
Inventors: |
Hammerslag; Gary R.;
(Steamboat Springs, CO) ; Mayberry; Mike; (Denver,
CO) ; Soderberg; Mark; (Evergreen, CO) |
Correspondence
Address: |
KNOBBE MARTENS OLSON & BEAR LLP
2040 MAIN STREET
FOURTEENTH FLOOR
IRVINE
CA
92614
US
|
Family ID: |
46329198 |
Appl. No.: |
11/841872 |
Filed: |
August 20, 2007 |
Related U.S. Patent Documents
|
|
|
|
|
|
Application
Number |
Filing Date |
Patent Number |
|
|
11263253 |
Oct 31, 2005 |
|
|
|
11841872 |
Aug 20, 2007 |
|
|
|
10459843 |
Jun 12, 2003 |
|
|
|
11263253 |
Oct 31, 2005 |
|
|
|
09993296 |
Nov 14, 2001 |
|
|
|
10459843 |
Jun 12, 2003 |
|
|
|
09956601 |
Sep 18, 2001 |
|
|
|
09993296 |
Nov 14, 2001 |
|
|
|
09388756 |
Sep 2, 1999 |
6289558 |
|
|
09956601 |
Sep 18, 2001 |
|
|
|
09337763 |
Jun 22, 1999 |
6202953 |
|
|
09388756 |
Sep 2, 1999 |
|
|
|
08917056 |
Aug 22, 1997 |
5934599 |
|
|
09337763 |
Jun 22, 1999 |
|
|
|
Current U.S.
Class: |
24/68SK ;
24/714.6 |
Current CPC
Class: |
Y10T 24/2183 20150115;
Y10T 24/3768 20150115; A43B 5/16 20130101; A43C 11/16 20130101;
A43C 11/004 20130101; A43C 11/165 20130101 |
Class at
Publication: |
024/068.0SK ;
024/714.6 |
International
Class: |
A43C 1/00 20060101
A43C001/00; A43C 11/00 20060101 A43C011/00 |
Claims
1. Footwear with a multi-zone lacing system, comprising: a sole; an
upper; first and second sides on the upper, separated by an
elongated lacing zone, the lacing zone having at least a first
section and a second section; a first lace, extending across the
first section of the lacing zone and having a first lace retractor;
a second lace, extending across the second section of the lacing
zone and having a second lace retractor.
2. Footwear with a multi-zone lacing system as in claim 1, wherein
the first section and the second section overlap.
3. Footwear with a multi-zone lacing system as in claim 1, wherein
at least the first lace retractor comprises a rotatable reel.
4. Footwear with a multi-zone lacing system as in claim 1, wherein
each of the first lace retractor and the second lace retractor
comprise a rotatable reel.
5. A system for tensioning a lace in footwear, comprising a first
lacing zone, a second lacing zone, a third lacing zone, a first
tightening system for tensioning the lace in the first zone, and a
second tightening system for tightening the lace in the second
zone; wherein lace tension in the third zone is automatically set
in response to the tighter of the lace tensions in the first and
second zones.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of U.S. patent
application Ser. No. 11/263,253, filed Oct. 31, 2005, pending,
which is a continuation-in-part of U.S. patent application Ser. No.
10/459,843, filed Jun. 12, 2003, pending, which is a
continuation-in-part of U.S. patent application Ser. No.
09/993,296, filed Nov. 14, 2001, abandoned, which is a
continuation-in-part of U.S. patent application Ser. No.
09/956,601, filed on Sep. 18, 2001, abandoned, which is a
continuation of U.S. patent application Ser. No. 09/388,756, filed
Sep. 2, 1999, now U.S. Pat. No. 6,289,558, which is a
continuation-in-part of U.S. patent application Ser. No.
09/337,763, filed on Jun. 22, 1999, now U.S. Pat. No. 6,202,953,
which is a continuation of U.S. patent application Ser. No.
08/917,056, filed Aug. 22, 1997, now U.S. Pat. No. 5,934,599. This
application also claims the benefit of U.S. Provisional Patent
Application No. 60/623,341, filed Oct. 29, 2004, and U.S.
Provisional Patent Application No. 60/704,831, filed Aug. 2, 2005.
Incorporate by Reference
[0002] This application hereby incorporates by reference U.S.
patent application Ser. No. 11/263,253, filed Oct. 31, 2005; U.S.
patent application Ser. No. 10/459,843 filed Jun. 12, 2003; U.S.
patent application Ser. No. 09/993,296 filed Nov. 14, 2001; Ser.
No. 09/956,601 filed on Sep. 18, 2001; U.S. Pat. No. 6,289,558,
issued Sep. 18, 2001; U.S. Pat. No. 6,202,953, issued Mar. 20,
2001; U.S. Pat. No. 5,934,599, issued Aug. 10, 1999; U.S.
Provisional Application No. 60/623,341, filed Oct. 29, 2004, and
U.S. Provisional Patent Application No. 60/704,831, filed Aug. 2,
2005, in their entireties.
BACKGROUND OF THE INVENTION
[0003] 1. Field of the Invention
[0004] The present invention relates to closure systems used in
combination in any of a variety of applications including clothing,
for example in a low-friction lacing system for footwear that
provides equilibrated tightening pressure across a wearer's
foot.
[0005] 2. Description of the Related Art
[0006] There currently exist a number of mechanisms and methods for
tightening a shoe or boot around a wearer's foot. A traditional
method comprises threading a lace in a zig-zag pattern through
eyelets that run in two parallel rows attached to opposite sides of
the shoe. The shoe is tightened by first tensioning opposite ends
of the threaded lace to pull the two rows of eyelets towards the
midline of the foot and then tying the ends in a knot to maintain
the tension. A number of drawbacks are associated with this type of
lacing system. First, laces do not adequately distribute the
tightening force along the length of the threaded zone, due to
friction between the lace and the eyelets, so that portions of the
lace are slack and other portions are in tension. Consequently, the
higher tensioned portions of the shoe are tighter around certain
sections of the foot, particularly the ankle portions which are
closer to the lace ends. This is uncomfortable and can adversely
affect performance in some sports.
[0007] Another drawback associated with conventional laces is that
it is often difficult to untighten or redistribute tension on the
lace, as the wearer must loosen the lace from each of the many
eyelets through which the laces are threaded. The lace is not
easily released by simply untightening the knot. The friction
between the lace and the eyelets often maintains the toe portions
and sometimes much of the foot in tension even when the knot is
released. Consequently, the user must often loosen the lace
individually from each of the eyelets. This is especially tedious
if the number of eyelets is high, such as in ice-skating boots or
other specialized high performance footwear.
[0008] Another tightening mechanism comprises buckles which clamp
together to tighten the shoe around the wearer's foot. Typically,
three to four or more buckles are positioned over the upper portion
of the shoe. The buckles may be quickly clamped together and drawn
apart to tighten and loosen the shoe around the wearer's foot.
Although buckles may be easily and quickly tightened and
untightened, they also have certain drawbacks. Specifically,
buckles isolate the closure pressure across three or four points
along the wearer's foot corresponding to the locations of the
buckles. This is undesirable in many circumstances, such as for the
use of sport boots where the wearer desires a force line that is
evenly distributed along the length of the foot. Another drawback
of buckles is that they are typically only useful for hard plastic
or other rigid material boots. Buckles are not as practical for use
with softer boots, such as ice skates or snowboard boots.
[0009] There is therefore a need for a tightening system for
footwear that does not suffer from the aforementioned drawbacks.
Such a system should automatically distribute lateral tightening
forces along the length of the wearer's ankle and foot. The
tightness of the shoe should desirably be easy to loosen and
incrementally adjust. The tightening system should close tightly
and should not loosen up with continued use.
SUMMARY OF THE INVENTION
[0010] There is provided in accordance with one aspect of the
present invention, a footwear lacing system. The system comprises a
footwear member including first and second opposing sides
configured to fit around a foot. A plurality of lace guide members
are positioned on the opposing sides. A lace is guided by the guide
members, the lace being rotationally connected to a spool that is
rotatable in a winding direction and an unwinding direction. A
tightening mechanism is attached to the footwear member, and
coupled to the spool, the tightening mechanism including a control
for winding the lace around the spool to place tension on the lace
thereby pulling the opposing sides towards each other. A safety
device is moveable between a secure position in which the spool is
unable to rotate in an unwinding direction, and a releasing
position in which the spool is free to rotate in an unwinding
direction.
[0011] In one embodiment, the lace is slideably positioned around
the guide members to provide a dynamic fit in response to movement
of the foot within the footwear. The guide members may have a
substantially C-shaped cross section.
[0012] Additionally, the tightening mechanism is a rotatable reel
that is configured to receive the lace. In accordance with one
embodiment, a knob rotates the spool and thereby winds the lace
about the spool. In some embodiments, rotating the knob in an
unwinding direction releases the spool and allows the lace to
unwind. A safety device can be attached, such as a lever, that
selectively allows the knob to rotate in an unwinding direction to
release the spool. Alternatively, the safety device can be a
rotatable release that is rotated separately from the knob to
release the spool.
[0013] In certain embodiments, the footwear lacing system is
attached to footwear having a first opposing side configured to
extend from one side of the shoe, across the upper midline of the
shoe, and to the opposing side of the shoe. As such, the reel can
be mounted to the first opposing side.
[0014] In one embodiment, the lace is formed of a polymeric
fiber.
[0015] According to another aspect of the footwear lacing system, a
closure system for footwear having an upper with a lateral side and
a medial side, the closure system comprising at least a first lace
guide attached to the lateral side of the upper, at least a second
lace guide attached to the medial side of the upper, and each of
the first and second lace guides comprising a lace pathway, a lace
slideably extending along the lace pathway of each of the first and
second lace guides. Additionally, a tightening reel of the footwear
for retracting the lace and thereby advancing the first lace guide
towards the second lace guide to tighten the footwear is positioned
on the footwear, and a lock is moveable between a coupled position
and an uncoupled position wherein the lock allows the reel to be
only rotatable in a forward direction when the lock is engaged, and
allows the reel to be rotatable in a reverse direction when the
lock is disengaged.
[0016] An embodiment also includes a closed loop lace wherein the
lace is permanently mounted in the reel. Accordingly, each of the
at least first and second lace guides comprise an open channel to
receive the closed loop lace.
[0017] According to another embodiment of the footwear lacing
system, a spool and lace unit is provided for use in conjunction
with a footwear lacing system comprises a spool having ratchet
teeth disposed on its periphery configured to interact with a pawl
for inhibiting relative rotation of the spool in at least one
direction, and a lace securely attached to the spool. Optionally,
the lace can be formed of a lubricious polymer having a relatively
low elasticity and high tensile strength. Alternatively, the lace
can be formed of a multi-strand polymeric cable. Alternatively, the
lace can be formed of a multi-strand metallic cable, preferably
with a lubricious polymer casing.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] FIG. 1 is a side view of a sport boot including a lacing
system configured in accordance with the present invention;
[0019] FIG. 2 is a front view of the sport boot of FIG. 1;
[0020] FIG. 3 is a perspective schematic view of the lacing system
of the sport boot of FIG. 1;
[0021] FIG. 4 is a top plan view of the multi-piece guide
member;
[0022] FIG. 5 is a side view of the sport boot including an ankle
support strap;
[0023] FIG. 6 is a front view of the sport boot including a central
lace guide member disposed adjacent the tongue of the boot;
[0024] FIG. 7 is a schematic front view of the instep portion of
the boot with a plurality of lace locking members disposed along
the lace pathway;
[0025] FIG. 8 is a front view of the instep portion of the
boot;
[0026] FIG. 9 is an enlarged view of the region within line 9 of
FIG. 8;
[0027] FIG. 10 is a top plan view of an alternative embodiment of a
lace guide;
[0028] FIG. 11 is a side view of the lace guide of FIG. 10;
[0029] FIG. 12 is a top view of the lace guide of FIG. 10 mounted
in a boot flap;
[0030] FIG. 13 is a cross-sectional view of the lace guide and boot
flap along line 13-13 of FIG. 12;
[0031] FIG. 14 is a side view of a second embodiment of the
tightening mechanism.
[0032] FIG. 15 is a top plan view showing one embodiment of the
footwear lacing system of the present invention attached to a shoe
that is shown in phantom.
[0033] FIG. 16 is a side elevational view of a shoe having another
embodiment of the footwear lacing system of the present invention
attached thereto.
[0034] FIG. 17 is a side elevational view of a shoe having yet
another embodiment of the footwear lacing system of the present
invention attached thereto.
[0035] FIG. 18 is a perspective view of an embodiment of a lacing
system having a protective element.
[0036] FIG. 19 is a side elevational view of the lacing system of
FIG. 18 showing the protective element.
[0037] FIG. 20 illustrates a perspective view of an embodiment of a
lacing system having an alternative protective element.
[0038] FIG. 21 is an exploded perspective view of an embodiment of
a self-winding tightening mechanism.
[0039] FIG. 22 is a top plan view of the mechanism of FIG. 21.
[0040] FIG. 23 is a section view of the mechanism of FIG. 22, taken
through line A-A.
[0041] FIG. 24 is a top plan view of one embodiment of a portion of
a self-winding tightening mechanism.
[0042] FIG. 25 is a section view of the mechanism of FIG. 24, taken
through line B-B.
[0043] FIG. 26 is a perspective view of one embodiment of a portion
of a self-winding tightening mechanism.
[0044] FIG. 27 is a perspective view of an embodiment of a spring
assembly for use in some embodiments of a self-winding tightening
mechanism.
[0045] FIG. 28 is a schematic plan view illustration of one
embodiment of a multi-zone lacing system.
[0046] FIG. 29A-D are perspective, end elevation, top plan and side
elevation views of one embodiment of a double-deck lace guide for
use in embodiments of a multi-zone lacing system.
[0047] FIG. 30A-D are perspective, end elevation, top plan and side
elevation views of one embodiment of a double-deck pass-through
lace guide for use in embodiments of a multi-zone lacing
system.
[0048] FIG. 31 is an exploded bottom perspective view of one
embodiment of a vamp structure.
[0049] FIG. 32 is an exploded top perspective view of one
embodiment of a vamp structure.
[0050] FIG. 33 is a detail view of an embodiment of a tightening
mechanism for use in a vamp structure.
[0051] FIG. 34 is a side elevation view of one embodiment of an
assembled vamp.
[0052] FIG. 35 is a perspective view of a lace guide comprising a
slot for use in some embodiments of a lacing system.
[0053] FIG. 36 is a perspective view of a lace guide comprising a
hook for use in some embodiments of a lacing system.
[0054] FIGS. 37A-C are schematic illustrations of embodiments of a
lacing system configured to double-up laces in desired
sections.
[0055] FIGS. 38A and 38B are side elevation views of one embodiment
of a component of a lacing system.
[0056] FIG. 39 is an exploded top perspective view of one
embodiment of a tightening mechanism.
[0057] FIGS. 40A through 40C are various views of one component of
a tightening mechanism.
[0058] FIG. 41 is a top perspective view of one component of a
tightening mechanism.
[0059] FIGS. 42A through 42E are various views of one component of
a tightening mechanism.
[0060] FIGS. 43A and 43B are various views of one component of a
tightening mechanism.
[0061] FIGS. 44A and 44B are top views of one embedment of a
tightening mechanism, shown engaged in FIG. 44A and disengaged in
FIG. 44B.
[0062] FIGS. 45A and 45B are cross sectional side views of one
embodiment of a tightening mechanism.
[0063] FIG. 46 is a cross sectional top perspective view of one
embodiment of a tightening mechanism.
[0064] FIGS. 47A through 47C are various views of one embodiment of
a lacing system mounted to an article of footwear.
[0065] FIGS. 48A and 48B are side elevation views of one embodiment
of a tightening mechanism.
[0066] FIGS. 49A and 49B are front and back perspective views of
one component of a tightening mechanism.
[0067] FIGS. 50A and 50B are various views of one embodiment of a
lacing system mounted to an article of footwear.
[0068] FIG. 51 is a top perspective view of a component of a lacing
system.
[0069] FIGS. 52A and 52B are front and perspective views,
respectively, of one embodiment of a tightening mechanism.
[0070] FIG. 53 is an exploded top perspective view of one
embodiment of a tightening mechanism.
[0071] FIGS. 54A through 54K are various views of one element that
may be included in an embodiment of a tightening mechanism
[0072] FIGS. 55A through 55F are various views of an assembled
component of an embodiment of a tightening mechanism.
[0073] FIGS. 56A through 56F are various views of an assembled
component of an embodiment of a tightening mechanism.
[0074] FIGS. 57A and 57F are various views of one component of an
embodiment of a tightening mechanism.
[0075] FIG. 58 is a bottom perspective exploded view of one
component of an embodiment of a tightening mechanism.
[0076] FIGS. 59A and 59B are cross sectional side views of a
component of an embodiment of a tightening mechanism.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0077] Referring to FIG. 1, there is disclosed one embodiment of a
sport boot 20 prepared in accordance with the present invention.
The sport boot 20 generally comprises an ice skating or other
action sport boot which is tightened around a wearer's foot using a
lacing system 22. The lacing system 22 includes a lace 23 (FIG. 2)
that is threaded through the boot 20 and attached at opposite ends
to a tightening mechanism 25, as described in detail below. As used
herein, the terms lace and cable have the same meaning unless
specified otherwise. The lace 23 is a low friction lace that slides
easily through the boot 20 and automatically equilibrates
tightening of the boot 20 over the length of the lacing zone, which
generally extends along the ankle and foot. Although the present
invention will be described with reference to an ice skating boot,
it is to be understood that the principles discussed herein are
readily applicable to any of a wide variety of footwear, and are
particularly applicable to sports shoes or boots suitable for snow
boarding, roller skating, skiing and the like.
[0078] The boot 20 includes an upper 24 comprising a toe portion
26, a heel portion 28, and an ankle portion 29 that surrounds the
wearer's ankle. An instep portion 30 of the upper 24 is interposed
between the toe portion 26 and the ankle portion 29. The instep
portion 30 is configured to fit around the upper part of the arch
of the medial side of the wearer's foot between the ankle and the
toes. A blade 31 (shown in phantom lines) extends downward from the
bottom of the boot 20 in an ice-skating embodiment.
[0079] FIG. 2 is a front elevational view of the boot 20. As shown,
the top of the boot 20 generally comprises two opposed closure
edges or flaps 32 and 34 that partially cover a tongue 36.
Generally, the lace 23 may be tensioned to draw the flaps 32 and 34
toward each other and tighten the boot 20 around the foot, as
described in detail below. Although the inner edges of the flaps 32
and 34 are shown separated by a distance, it is understood that the
flaps 32 and 34 could also be sized to overlap each other when the
boot 20 is tightened, such as is known with ski footwear. Thus,
references herein to drawing opposing sides of footwear towards
each other refers to the portion of the footwear on the sides of
the foot. This reference is thus generic to footwear in which
opposing edges remain spaced apart even when tight (e.g. tennis
shoes) and footwear in which opposing edges may overlap when tight
(e.g. certain snow skiing boots). In both, tightening is
accomplished by drawing opposing sides of the footwear towards each
other.
[0080] Referring to FIG. 2, the tongue 36 extends rearwardly from
the toe portion 26 toward the ankle portion 29 of the boot 20.
Preferably, the tongue 36 is provided with a low friction top
surface 37 to facilitate sliding of the flaps 32 and 34 and lace 23
over the surface of the tongue 32 when the lace 23 is tightened.
The low friction surface 37 may be formed integrally with the
tongue 32 or applied thereto such as by adhesives, heat bonding,
stitching or the like. In one embodiment, the surface 37 is formed
by adhering a flexible layer of nylon or polytetrafluoroethylene to
the top surface of the tongue 36. The tongue 36 is preferably
manufactured of a soft material, such as leather.
[0081] The upper 24 may be manufactured from any from a wide
variety of materials known to those skilled in the art. In the case
of a snow board boot, the upper 24 is preferably manufactured from
a soft leather material that conforms to the shape of the wearer's
foot. For other types of boots or shoes, the upper 24 may be
manufactured of a hard or soft plastic. It is also contemplated
that the upper 24 could be manufactured from any of a variety of
other known materials.
[0082] As shown in FIG. 2, the lace 23 is threaded in a crossing
pattern along the midline of the foot between two generally
parallel rows of side retaining members 40 located on the flaps 32
and 34. In the illustrated embodiment, the side retaining members
40 each consist of a strip of material looped around the top and
bottom edges of the flaps 32 and 34 so as to define a space in
which guides 50 are positioned. The lace 23 slides through the
guides 50 during tightening and untightening of the lace 23, as
described more fully below. In the illustrated embodiment, there
are three side retaining members 40 on each flap 32, 34 although
the number of retaining members 40 may vary. In some embodiments,
four, five or six or more retaining members 40 may be desirable on
each side of the boot.
[0083] In certain boot designs, it may be possible during the
tightening process for an opposing pair of lace guides to "bottom
out" and come in contact with each other before that portion of the
boot is suitably tightened. Further tightening of the system will
not produce further tightening at that point. Rather, other
portions of the boot which may already be sized appropriately would
continue to tighten. In the embodiment illustrated in FIG. 2, the
side retaining members 40 each consist of a strip of material
looped around the guides 50. Additional adjustability may be
achieved by providing a releasable attachment between the side
retaining members 40 and the corresponding flap 32 or 34 of the
shoe. In this manner, the side retaining member 40 may be moved
laterally away from the midline of the foot to increase the
distance between opposing lace guides.
[0084] One embodiment of the adjustable side retaining member 40
may be readily constructed, that will appear similar to the
structure disclosed in FIG. 2. In the adjustable embodiment, a
first end of the strip of material is attached to the corresponding
flap 32 or 34 using conventional means such as rivets, stitching,
adhesives, or others known in the art. The strip of material loops
around the guide 50, and is folded back over the outside of the
corresponding flap 32 or 34 as illustrated. Rather than stitching
the top end of the strip of material to the flap, the corresponding
surfaces between the strip of material and the flap may be provided
with a releasable engagement structure such as hook and loop
structures (e.g., Velcro.RTM.), or other releasable engagement
locks or clamps which permits lateral-medial adjustability of the
position of the guide 50 with respect to the edge of the
corresponding flap 32 or 34.
[0085] The guides 50 may be attached to the flaps 32 and 34 or to
other spaced apart portions of the shoe through any of a variety of
manners, as will be appreciated by those of skill in the art in
view of the disclosure herein. For example, the retaining members
40 can be deleted and the guide 50 sewn directly onto the surface
of the flap 32 or 34 or opposing sides of the upper. Stitching the
guide 50 directly to the flap 32 or 34 may advantageously permit
optimal control over the force distribution along the length of the
guide 50. For example, when the lace 23 is under relatively high
levels of tension, the guide 50 may tend to want to bend and to
possibly even kink near the curved transition in between
longitudinal portion 51 and transverse portion 53 as will be
discussed. Bending of the guide member under tension may increase
friction between the guide member and the lace 23, and, severe
bending or kinking of the guide member 50 may undesirably interfere
with the intended operation of the lacing system. Thus, the
attachment mechanism for attaching the guide member 50 to the shoe
preferably provides sufficient support of the guide member to
resist bending and/or kinking. Sufficient support is particularly
desirable on the inside radius of any curved portions particularly
near the ends of the guide member 50.
[0086] As shown in FIGS. 1 and 2, the lace 23 also extends around
the ankle portion 29 through a pair of upper retaining members 44a
and 44b located on the ankle portion 29. The upper retaining
members 44a and 44b each comprise a strip of material having a
partially raised central portion that defines a space between the
retaining members 44 and the upper 24. An upper guide member 52
extends through each of the spaces for guiding the lace 23 around
either side of the ankle portion 29 to the tightening mechanism
25.
[0087] FIG. 3 is a schematic perspective view of the lacing system
22 of the boot 20. As shown, each of the side and top guide members
50 and 52, has a tube-like configuration having a central lumen 54.
Each lumen 54 has an inside diameter that is larger than the
outside diameter of the lace 23 to facilitate sliding of the lace
23 through the side and top guide members 50, 52 and prevent
binding of the lace 23 during tightening and untightening. In one
embodiment, the inside diameter of the lumen is approximately 0.040
inches, to cooperate with a lace having an outside diameter of
about 0.027''. However, it will be appreciated that the diameter of
the lumen 54 can be varied to fit specific desired lace dimensions
and other design considerations. The wall thickness and composition
of the guides 50, 52 may be varied to take into account the
physical requirements imposed by particular shoe designs.
[0088] Thus, although the guides 50 are illustrated as relatively
thin walled tubular structures, any of a variety of guide
structures may be utilized as will be apparent to those of skill in
the art in view of the disclosure herein. For example, either
permanent (stitched, glued, etc.) or user removable (Velcro, etc.)
flaps 40 may be utilized to hold down any of a variety of guide
structures. In one embodiment, the guide 50 is a molded block
having a lumen extending therethrough. Modifications of the
forgoing may also be accomplished, such as by extending the length
of the lace pathway in a structure such as that illustrated in FIG.
4, such that the overall part has a shallow "U" shaped
configuration which allows it to be conveniently retained by the
retention structure 40. Providing a guide member 50 having
increased structural integrity over that which would be achieved by
the thin tube illustrated in FIG. 2 may be advantageous in
embodiments of the invention where the opposing guides 50 may be
tightened sufficiently to "bottom out" against the opposing
corresponding guide, as will be apparent to those of skill in the
art in view of the disclosure herein. Solid and relatively harder
lace guides as described above may be utilized throughout the boot,
but may be particularly useful in the lower (e.g. toe) portion of
the boot.
[0089] In general, each of the guide members 50 and 52 defines a
pair of openings 49 that communicate with opposite ends of the
lumen 54. The openings 49 function as inlets/outlets for the lace
23. The openings desirably are at least as wide as the
cross-section of the lumen 54.
[0090] As may be best seen in FIG. 3, each top guide 52 has an end
55 which is spaced apart from a corresponding side guide 50 on the
opposing side of the footwear, with the lace 23 extending
therebetween. As the system is tightened, the spacing distance will
be reduced. For some products, the wearer may prefer to tighten the
toe or foot portion more than the ankle. This can be conveniently
accomplished by limiting the ability of the side guide 50 and top
guide 52 to move towards each other beyond a preselected minimum
distance during the tightening process. For this purpose, a
selection of spacers having an assortment of lengths may be
provided with each system. The spacers may be snapped over the
section of lace 23 between a corresponding end 55 of top guide 52
and side guide 50. When the ankle portion of the boot is
sufficiently tight, yet the wearer would like to additionally
tighten the toe or foot portion of the boot, a spacer having the
appropriate length may be positioned on the lace 23 in-between the
top guide 52 and side guide 50. Further tightening of the system
will thus not be able to draw the top guide 52 and corresponding
side guide 50 any closer together.
[0091] The stop may be constructed in any of a variety of ways,
such that it may be removably positioned between the top guide 52
and side guide 50 to limit relative tightening movement. In one
embodiment, the stop comprises a tubular sleeve having an axial
slot extending through the wall, along the length thereof The
tubular sleeve may be positioned on the boot by advancing the slot
over the lace 23, as will be apparent to those of skill in the art.
A selection of lengths may be provided, such as 1/2 inch, 1 inch,
1-1/2 inch, and every half inch increment, on up to 3 or 4 inches
or more, depending upon the position of the reel on the boot and
other design features of a particular embodiment of the boot.
Increments of 1/4 inch may also be utilized, if desired.
[0092] FIGS. 30-33 illustrate an embodiment of a dynamic spacer
configured to allow a user to selectively determine an amount of
spacing between portions of a footwear item. The structure of FIGS.
30-33 comprises a pair of stops 920 carried by first and second
compression bands 902, 904 sandwiched between a bottom cover 906
and a top cover 908. A drive mechanism 910 comprising a knob 940
can be provided to move the stops 920 laterally.
[0093] In use, a dynamic spacer such as that shown in FIGS. 30-33,
can be positioned on a tongue between the flaps (or vamps) of a
footwear item. In some embodiments, the dynamic spacer is
positioned between a pair of lace guides. As described above, when
the laces 23 are tightened, the flaps will be drawn towards one
another. However, in the region of the dynamic spacer, the flap
edges (or the lace guides) will abut the stops 920, thereby
preventing further tightening of that region of the footwear item.
The dynamic spacer 900 is generally configured to allow a user to
adjust a spacing between the stops, and thereby to adjust an amount
of tightening in the region of the dynamic spacer. As above, in
some embodiments, a wearer may wish to provide more spacing (i.e. a
looser fit) at a toe portion of a footwear item. Alternatively, in
other embodiments, a user may wish to provide more spacing in an
upper section of a footwear item.
[0094] The stops 920 are generally carried by the first and second
compression bands 902, 904. With reference to FIGS. 30 and 31 each
of the first 902 and second 904 compression bands comprises an
elongate slot 922 adjacent a distal end 912, 914 of the compression
bands 902, 904. Each slot 922 includes a plurality of teeth 924 on
one edge, the other edge remaining substantially smooth and free of
teeth. The bands 902, 904 are positioned as shown in FIGS. 30 and
31 such that the slots 922 overlap, thereby positioning the teeth
924 of each compression band 902, 904 on opposite sides of a
centerline of the dynamic spacer 900.
[0095] Adjacent to their proximal ends 932, 934, the compression
bands 902, 904 can also include attachment holes 936 configured to
be secured to the stops 920. In the embodiments illustrated in
FIGS. 30 and, the stops 920 can be secured to the compression
straps 902, 904 by fasteners 926 which can extend through the stops
920, through slots in the top cover 908, through the fastener holes
936 in the compression bands 902, 904 and through slots in the
bottom cover 906. In some embodiments, the fasteners 926 can also
comprise a retaining member positioned below the bottom cover 906
to retain the fastener in the spacer. The fasteners can be rivets,
screws, bolts, pins, or any other suitable devices. Similarly, the
retaining members can be crimped rivet ends, washers, nuts, or any
other suitable device.
[0096] FIGS. 30-62 illustrate embodiments of a drive mechanism 910
for use with a dynamic spacer 900. The drive mechanism 910
generally comprises a knob 940 configured to rotate in a direction
corresponding to a laterally outward movement of the stops 920
(i.e. a counter-clockwise direction in the illustrated embodiment).
In some embodiments, the knob 940 is also configured to be locked
or otherwise prevented from rotating in a direction corresponding
to a laterally inward movement of the stops 920 (i.e. a clockwise
direction in the illustrated embodiment). In the illustrated
embodiment, the knob 940 comprises a plurality of face ratchet
teeth 942 on an underside thereof The top cover 908 can also be
provided with a plurality of mating face ratchet teeth 944
configured to engage the teeth 942 of the knob 940. In the
illustrated embodiments, the mating ratchet teeth 942, 944 are
generally configured to resist a clockwise rotation of the knob
940, thereby preventing the stops 920 from being pushed laterally
inwards by the footwear flap edges. In alternative embodiments,
other one-way rotational structures and/or other locking structures
can also be used. For example, pins, latches, levers, or other
devices can be used to prevent rotation of the knob and/or lateral
movement of the stops 920. In some embodiments, the knob 940 is
also configured to be releasable in order to allow the stops 920 to
move laterally inwards in order to allow for increased tightening
in the area of the dynamic spacer 900.
[0097] In the illustrated embodiment, the knob 940 also includes a
shaft 950 extending from its underside and including a drive gear
952 configured to engage the teeth 924 of each of the first 902 and
second 904 compression bands. The gear 952 can be any suitable type
as desired. The number and/or a spacing of teeth provided on the
gear can be varied depending on a degree of mechanical advantage
desired. In alternative embodiments, additional gears can also be
provided in order to provide additional mechanical advantage to the
drive mechanism. For example, in some embodiments, a substantial
mechanical advantage may be desirable in order to allow a wearer to
more easily loosen a section of a footwear item by turning the knob
940 and driving the stops 920 further apart.
[0098] In some embodiments, the shaft 950 is of sufficient length
that the distal end 954 of the shaft 950 extends through a central
aperture 960 in the bottom cover 906 when the dynamic spacer 900 is
assembled. A spring washer 962 can be secured to the distal end 954
of the shaft 950 after the shaft 950 has been inserted through the
central aperture 960 in the bottom cover 906. The spring washer 962
is generally configured to bias the knob 940 downward along the
axis of the shaft 950, thereby maintaining the ratchet teeth 942,
944 in engagement with one another. In some embodiments, the spring
washer 962 can also be configured to allow a degree of upward
motion of the knob 940 in order to allow the face ratchet teeth 942
to disengage, thereby allowing the stops 920 to move laterally
inward.
[0099] In some embodiments, the top cover 908 and bottom cover 906
include rails 964 configured to retain and guide the first and
second compression bands 902, 904 along a desired path. A material
of the compression bands 902, 904 and a space between the top and
bottom covers 906, 908 are generally selected to prevent the
compression bands from buckling under the compressive force that
will be applied by the footwear flap edges engaging the stops
920.
[0100] The dynamic spacer 900 can be secured to a footwear item by
attaching the bottom and/or top covers 906, 908 to a portion of a
footwear item by any suitable means, such as rivets, adhesives,
stitches, hook-and-loop fasteners, etc. Additionally, in some
embodiments, the dynamic spacer 900 can be configured to releasably
attach to portions of a footwear item. For example, in some
embodiments, a tongue of a boot may comprise a plurality of
attachment locations for a dynamic spacer, such as at an upper
section, an instep section, a toe section, etc. A dynamic spacer
can then be removed from any of the attachment locations and moved
to another of the attachment locations for a different fit. In
still further embodiments, a dynamic spacer need not be attached to
any portion of a footwear item. For example, a dynamic spacer can
simply be held in place by friction created by a compressive force
between the flaps of the footwear.
[0101] In alternative embodiments, other drive mechanisms can also
be provided. For example, a rack-and-pinion type drive gear and
teeth can be oriented such that a rotational axis of the drive gear
is positioned perpendicular to the orientation of the illustrated
embodiments. In still further embodiments, other mechanical
transmission elements, such as worm screws, cable/pulley
arrangements, or lockable sliding elements, can alternatively be
used to provide an adjustable position between the stops 920.
[0102] In FIG. 3, the top guide 52 is illustrated for simplicity as
unattached to the corresponding side flap 32. However, in an actual
product, the top guide 52 is preferably secured to the side flap
32. For example, upper retaining member 44a, discussed above, is
illustrated in FIG. 2. Alternatively, the top guide 52 may extend
within the material of or between the layers of the side flap 32.
As a further alternative, or in addition to the foregoing, the end
55 of top guide 52 may be anchored to the side flap 32 using any of
a variety of tie down or clamping structures. The lace 23 may be
slideably positioned within a tubular sleeve extending between the
reel and the tie down at the end 55 of the sleeve.
[0103] Any of a variety of flexible tubular sleeves may be
utilized, such as a spring coil with or without a polymeric jacket
similar to that used currently on bicycle brake and shift cables.
The use of a flexible but axially noncompressible sleeve for
surrounding the lace 23 between the reel and the tie down at the
end 55 isolates the tightening system from movement of portions of
the boot, which may include hinges or flexibility points as is
understood in the art. The tie down may comprise any of a variety
of structures including grommets, rivets, staples, stitched or
adhesively bonded eyelets, as will be apparent to those of skill in
the art in view of the disclosure herein.
[0104] In the illustrated embodiment, the side guide members 50
each have a generally U-shape that opens towards the midline of the
shoe. Preferably, each of the side guide members 50 comprise a
longitudinal portion 51 and two inclined or transverse portions 53
extending therefrom. The length of the longitudinal portion 51 may
be varied to adjust the distribution of the closing pressure that
the lace 23 applies to the upper 24 when the lace 23 is under
tension. In addition, the length of the longitudinal portion 51
need not be the same for all guide members 50 on a particular shoe.
For example, the longitudinal portion 51 may be shortened near the
ankle portion 29 to increase the closing pressure that the lace 23
applies to the ankles of the wearer. In general, the length of the
longitudinal portion 51 will fall within the range of from about
1/2'' to about 3'', and, in some embodiments, within the range of
from about 1/4'' to about 4''. In one snowboard application, the
longitudinal portion 51 had a length of about 2''. The length of
the transverse portion 53 is generally within the range of from
about 1/8'' to about 1''. In one snowboard embodiment, the length
of transverse portion 53 was about 1/2''. Different specific length
combinations can be readily optimized for a particular boot design
through routine experimentation by one of ordinary skill in the art
in view of the disclosure herein.
[0105] In between the longitudinal portion 51 and transverse
portion 53 is a curved transition. Preferably, the transition has a
substantially uniform radius throughout, or smooth progressive
curve without any abrupt edges or sharp changes in radius. This
construction provides a smooth surface over which the lace 23 can
slide, as it rounds the corner. The transverse section 53 can in
some embodiments be deleted, as long as a rounded cornering surface
is provided to facilitate sliding of the lace 23. In an embodiment
which has a transverse section 53 and a radiused transition, with a
guide member 50 having an outside diameter of 0.090'' and a lace 23
having an outside diameter of 0.027'', the radius of the transition
is preferably greater than about 0.1'', and generally within the
range of from about 0.125'' to about 0.4''.
[0106] Referring to FIG. 3, the upper guide members 52 extend
substantially around opposite sides of the ankle portion 29. Each
upper guide member 52 has a proximal end 56 and a distal end 55.
The distal ends 55 are positioned near the top of the tongue 36 for
receipt of the lace 23 from the uppermost side guide members 50.
The proximal ends 56 are coupled to the tightening mechanism 25. In
the illustrated embodiment, the proximal ends 56 include
rectangular coupling mounts 57 that engage with the tightening
mechanism 25 for feeding the ends of the lace 23 therein, as
described more fully below. The guide members 50 and/or 52 are
preferably manufactured of a low friction material, such as a
lubricous polymer or metal, that facilitates the slideability of
the lace 23 therethrough. Alternatively, the guides 50, 52 can be
made from any convenient substantially rigid material, and then be
provided with a lubricous coating on at least the inside surface of
lumen 54 to enhance slideability. The guide members 50 and 52 are
preferably substantially rigid to prevent bending and kinking of
the guide members 50, 52 and/or the lace 23 within any of the guide
members 50 and 52 as the lace 23 is tightened. The guide members
50, 52 may be manufactured from straight tube of material that is
cold bent or heated and bent to a desired shape.
[0107] As an alternative to the previously described tubular guide
members, the guide members 50 and/or 52 comprise an open channel
having, for example, a semicircular or "U" shaped cross section.
The guide channel is preferably mounted on the boot such that the
channel opening faces away from the midline of the boot, so that a
lace under tension will be retained therein. One or more retention
strips, stitches or flaps may be provided for "closing" the open
side of the channel, to prevent the lace from escaping when tension
on the lace is released. The axial length of the channel can be
preformed in a generally U configuration like the illustrated
tubular embodiment, and may be continuous or segmented as described
in connection with the tubular embodiment.
[0108] Several guide channels may be molded as a single piece, such
as several guide channels molded to a common backing support strip
which can be adhered or stitched to the shoe. Thus, a right lace
retainer strip and a left lace retainer strip can be secured to
opposing portions of the top or sides of the shoe to provide a
right set of guide channels and a left set of guide channels.
[0109] With reference to FIG. 4, the gap 206 is elongated so that
it defines a lace pathway that functions as the lumen 54 for the
lace 23. The lumen 54 preferably includes an elongate region 209
that extends generally lengthwise along the edges of the flaps 32
or 34 when the guide member 199 is mounted on the boot. The
elongate region 209 may be straight or may be defined by a smooth
curve along the length thereof, such as a continuous portion of a
circle or ellipse. As an example, the elongate region 209 may be
defined by a portion of an ellipse having a major axis of about 0.5
inches to about 2 inches and a minor axis of about 0.25 inches to
about 1.5 inches. In one embodiment, the major axis is
approximately 1.4 inches and the minor axis is about 0.5 inches.
The lumen 54 further includes a transverse region 210 on opposite
ends of the elongate region 209. The transverse region 210 extends
at an incline to the edges of the flaps 32 and 34. Alternatively,
the elongate region 209 and the transverse region 210 may be merged
into one region having a continuous circular or elliptical profile
to spread load evenly along the length of the lumen 54 and thereby
reduce total friction in the system.
[0110] Referring to FIG. 4, each of the guide members 199 has a
predetermined distance between the first opening 207a and second
opening 207b to the lace pathway therein. The effective linear
distance between the first and second openings to the lace pathway
may affect the fit of the boot.
[0111] The lace 23 may be formed from any of a wide variety of
polymeric or metal materials or combinations thereof, which exhibit
sufficient axial strength and bendability for the present
application. For example, any of a wide variety of solid core
wires, solid core polymers, or multi-filament wires or polymers,
which may be woven, braided, twisted or otherwise oriented can be
used. A solid or multi-filament metal core can be provided with a
polymeric coating, such as PTFE or others known in the art, to
reduce friction. In one embodiment, the lace 23 comprises a
stranded cable, such as a 7 strand by 7 strand cable manufactured
of stainless steel. In order to reduce friction between the lace 23
and the guide members 50, 52 through which the lace 23 slides, the
outer surface of the lace 23 is preferably coated with a lubricous
material, such as nylon or Teflon. In a preferred embodiment, the
diameter of the lace 23 ranges from 0.024 inches to 0.060 inches
and is preferably 0.027 inches. The lace 23 is desirably strong
enough to withstand loads of at least 40 pounds and preferably at
least about 90 pounds. In certain embodiments the lace is rated at
least about 100 pounds up to as high as 200 pounds or more. A lace
23 of at least five feet in length is suitable for most footwear
sizes, although smaller or larger lengths could be used depending
upon the lacing system design.
[0112] The lace 23 may be formed by cutting a piece of cable to the
desired length. If the lace 23 comprises a braided or stranded
cable, there may be a tendency for the individual strands to
separate at the ends or tips of the lace 23, thereby making it
difficult to thread the lace 23 through the openings in the guide
members 50, 52. As the lace 23 is fed through the guide members,
the strands of the lace 23 easily catch on the curved surfaces
within the lace guide members. The use of a metallic lace, in which
the ends of the strands are typically extremely sharp, also
increases the likelihood of the cable catching on the guide members
during threading. As the tips of the strands catch on the guide
members and/or the tightening mechanism, the strands separate,
making it difficult or impossible for the user to continue to
thread the lace 23 through the tiny holes in the guide members
and/or the tightening mechanism. Unfortunately, unstranding of the
cable is a problem unique to the present replaceable-lace system,
where the user may be required to periodically thread the lace
through the lace guide members and into the corresponding
tightening mechanism.
[0113] One solution to this problem is to provide the tips or ends
59 of the lace 23 with a sealed or bonded region 61 wherein the
individual strands are retained together to prevent separation of
the strands from one another. For clarity of illustration, the
bonded region 61 is shown having an elongate length. However, the
bonded region 61 may also be a bead located at just the extreme tip
of the lace 23 and, in one embodiment, could be a bonded tip
surface as short as 0.002 inch or less.
[0114] After the 7.times.7 multistrand stainless steel cable
described above has been tightened and untightened a number of
times, the cable tends to kink or take a set. Kink resistance of
the cable may be improved by making the cable out of a nickel
titanium alloy such as nitinol. Other materials may provide
desirable kink resistance, as will be appreciated by those of skill
in the art in view of the disclosure herein. In one particular
embodiment, a 1.times.7 multi-strand cable may be constructed
having seven nitinol strands, each with a diameter within the range
of from about 0.005 inches to about 0.015 inches woven together. In
one embodiment, the strand has a diameter of about 0.010 inches,
and a 1.times.7 cable made with that strand has an outside diameter
("OD") of about 0.030 inches. The diameter of the nitinol strands
may be larger than a corresponding stainless steel embodiment due
to the increased flexibility of nitinol, and a 1.times.7
construction and in certain embodiments a 1.times.3 construction
may be utilized.
[0115] In a 1.times.3 construction, three strands of nitinol, each
having a diameter within the range of from about 0.007 inches to
about 0.025 inches, preferably about 0.015 inches are drawn and
then swaged to smooth the outside. A drawn multistrand cable will
have a nonround cross-section, and swaging and/or drawing makes the
cross-section approximately round. Swaging and/or drawing also
closes the interior space between the strands, and improves the
crush resistance of the cable. Any of a variety of additives or
coatings may also be utilized, such as additives to fill the
interstitial space between the strands and also to add lubricity to
the cable. Additives such as adhesives may help hold the strands
together as well as improve the crush resistance of the cable.
Suitable coatings include, among others, PTFE, as will be
understood in the art.
[0116] In an alternate construction, the lace or cable comprises a
single strand element. In one application, a single strand of a
nickel titanium alloy wire such as nitinol is utilized. Advantages
of the single strand nitinol wire include both the physical
properties of nitinol, as well as a smooth outside diameter which
reduces friction through the system. In addition, durability of the
single strand wire may exceed that of a multi strand since the
single strand wire does not crush and good tensile strength or load
bearing capacity can be achieved using a small OD single strand
wire compared to a multi strand braided cable. Compared to other
metals and alloys, nitinol alloys are extremely flexible. This is
useful since the nitinol laces are able to navigate fairly tight
radii curves in the lace guides and also in the small reel.
Stainless steel or other materials tend to kink or take a set if a
single strand was used, so those materials are generally most
useful in the form of a stranded cable. However, stranded cables
have the disadvantage that they can crush in the spool when the
lace is wound on top of itself In addition, the stranded cables are
not as strong for a given diameter as a monofilament wire because
of the spaces in between the strands. Strand packing patterns in
multistrand wire and the resulting interstitial spaces are well
understood in the art. For a given amount of tensile strength, the
multistrand cables therefore present a larger bulk than a single
filament wire. Since the reel is preferably minimized in size the
strongest lace for a given diameter is preferred. In addition, the
stranded texture of multistrand wires create more friction in the
lace guides and in the spool. The smooth exterior surface of a
single strand creates a lower friction environment, better
facilitating tightening, loosening and load distribution in the
dynamic fit of the present invention.
[0117] Single strand nitinol wires having diameters within the
range of from about 0.020 inches to about 0.040 inches may be
utilized, depending upon the boot design and intended performance.
In general, diameters which are too small may lack sufficient load
capacity and diameters which are too large may lack sufficient
flexibility to be conveniently threaded through the system. The
optimal diameter can be determined for a given lacing system design
through routine experimentation by those of skill in the art in
view of the disclosure herein. In many boot embodiments, single
strand nitinol wire having a diameter within the range of from
about 0.025 inches to about 0.035 inches may be desirable. In one
embodiment, single strand wire having a diameter of about 0.030
inches is utilized.
[0118] The lace may be made from wire stock, shear cut or otherwise
severed to the appropriate length. In the case of shear cutting, a
sharpened end may result. This sharpened end is preferably removed
such as by deburring, grinding, and/or adding a solder ball or
other technique for producing a blunt tip. In one embodiment, the
wire is ground or coined into a tapered configuration over a length
of from about 1/2 inch to about 4 inches and, in one embodiment, no
more than about 2 inches. The terminal ball or anchor is preferably
also provided as discussed below. Tapering the end of the nitinol
wire facilitates feeding the wire through the lace guides and into
the spool due to the increased lateral flexibility of the reduced
cross section.
[0119] Provision of an enlarged cross sectional area structure at
the end of the wire, such as by welding, swaging, coining
operations or the use of a melt or solder ball, may be desirable in
helping to retain the lace end within the reel as well as
facilitating feeding the lace end through the lace guides and into
the reel. In one embodiment of the reel, discussed elsewhere
herein, the lace end is retained within the reel under compression
by a set screw. While set screws may provide sufficient retention
in the case of a multi strand wire, set screw compression on a
single stand cable may not produce sufficient retention force
because of the relative crush resistance of the single strand. The
use of a solder ball or other enlarged cross sectional area
structure at the end of the lace can provide an interference fit
behind the set screw, to assist retention within the reel.
[0120] In one example, a 0.030 inch diameter single strand lace is
provided with a terminal ball having a diameter within the range of
from about 0.035 inches to about 0.040 inches. In addition to or as
an alternative to the terminal ball or anchor, a slight angle or
curve may be provided in the tip of the lace. This angle may be
within the range of from about 5.degree. to about 25.degree., and,
in one embodiment about 15.degree.. The angle includes
approximately the distal 1/8 inch of the lace. This construction
allows the lace to follow tight curves better, and may be combined
with a rounded or blunted distal end which may assist navigation
and locking within the reel. In one example, a single strand wire
having a diameter of about 0.030 inches is provided with a terminal
anchor having a diameter of at least about 0.035 inches. Just
proximal to the anchor, the lace is ground to a diameter of about
0.020 inches, which tapers over a distance of about an inch in the
proximal direction up to the full 0.030 inches. Although the term
"diameter" is utilized to describe the terminal anchor, Applicant
contemplates nonround anchors such that a true diameter is not
present. In a noncircular cross-section embodiment, the closest
approximation of the diameter is utilized for the present
purposes.
[0121] As an alternative terminal anchor on the lace, a molded
piece of plastic or other material may be provided on the end of
each single strand. In a further variation, each cable end is
provided with a detachable threading guide. The threading guide may
be made from any of a variety of relatively stiff plastics like
nylon, and be tapered to be easily travel around the corners of the
lace guides. After the lace is threaded through the lace guides,
the threading guide may be removed from the lace and discarded, and
the lace may be then installed into the reel.
[0122] The terminal anchor on the lace may also be configured to
interfit with any of a variety of connectors on the reel. Although
set screws are a convenient mode of connection, the reel may be
provided with a releasable mechanism to releasably receive the
larger shaped end of the lace which snaps into place and is not
removable from the reel unless it is released by an affirmative
effort such as the release of a lock or a lateral movement of the
lace within a channel. Any of a variety of releasable interference
fits may be utilized between the lace and the reel, as will be
apparent to those of skill in the art in view of the disclosure
herein.
[0123] As shown in FIG. 3, the tightening mechanism 25 is mounted
to the rear of the upper 24 by fasteners 64. Although the
tightening mechanism 25 is shown mounted to the rear of the boot
20, it is understood that the tightening mechanism 25 could be
located at any of a wide variety of locations on the boot 20. In
the case of an ice skating boot, the tightening mechanism is
preferably positioned over a top portion of the tongue 36. The
tightening mechanism 25 may alternatively be located on the bottom
of the heel of the boot, on the medial or the lateral sides of the
upper or sole, as well as anywhere along the midline of the shoe
facing forward or upward. Location of the tightening mechanism 25
may be optimized in view of a variety of considerations, such as
overall boot design as well as the intended use of the boot. The
shape and overall volume of the tightening mechanism 25 can be
varied widely, depending upon the gear train design, and the
desired end use and location on the boot. A relatively low profile
tightening mechanism 25 is generally preferred. The mounted profile
of the tightening mechanism 25 can be further reduced by recessing
the tightening mechanism 25 into the wall or tongue of the boot.
Boots for many applications have a relatively thick wall, such as
due to structural support and/or thermal insulation and comfort
requirements. The tightening mechanism may be recessed into the
wall of the boot by as much as 3/4'' or more in some locations and
for some boots, or on the order of about 1/8'' or 1/2'' for other
locations and/or other boots, without adversely impacting the
comfort and functionality of the boot.
[0124] Any of a variety of spool or reel designs can be utilized in
the context of the present invention, as will be apparent to those
of skill in the art in view of the disclosure herein.
[0125] Depending upon the gearing ratio and desired performance,
one end of the lace can be fixed to a guide or other portion of the
boot and the other end is wound around the spool. Alternatively,
both ends of the lace can be fixed to the boot, such as near the
toe region and a middle section of the lace is attached to the
spool.
[0126] Any of a variety of attachment structures for attaching the
ends of the lace to the spool can be used. In addition to the
illustrated embodiment, the lace may conveniently be attached to
the spool by threading the lace through an aperture and providing a
transversely oriented set screw so that the set screw can be
tightened against the lace and to attach the lace to the spool. The
use of set screws or other releasable clamping structures
facilitates disassembly and reassembly of the device, and
replacement of the lace as will be apparent to those of skill in
the art.
[0127] In any of the embodiments disclosed herein, the lace may be
rotationally coupled to the spool either at the lace ends, or at a
point on the lace that is spaced apart from the ends. In addition,
the attachment may either be such that the user can remove the lace
with or without special tools, or such that the user is not
intended to be able to remove the lace from the spool. Although the
device is disclosed primarily in the context of a design in which
the lace ends are attached to the spool, the lace ends may
alternatively be attached elsewhere on the footwear. In this
design, an intermediate point on the lace is connected to the spool
such as by adhesives, welding, interference fit or other attachment
technique. In one design the lace extends through an aperture which
extends through a portion of the spool, such that upon rotation of
the spool, the lace is wound around the spool. The lace ends may
also be attached to each other, to form a continuous lace loop.
[0128] It is contemplated that a limit on the expansion of portions
of the boot due to the sliding of the lace 23 could be accomplished
such as through one or more straps that extend transversely across
the boot 20 at locations where an expansion limit or increased
tightness or support are desired. For instance, a strap could
extend across the instep portion 30 from one side of the boot 20 to
another side of the boot. A second or lone strap could also extend
around the ankle portion 29.
[0129] With reference to FIG. 5, an expansion limiting strap 220 is
located on the ankle portion of the boot 20 to supplement the
closure provided by the lace 23 and provide a customizable limit on
expansion due to the dynamic fit achieved by the lacing system of
the present invention. The limit strap 220 may also prevent or
inhibit the wearer's foot from unintentionally exiting the boot 20
if the lace 20 is unlocked or severed or the reel fails. In the
illustrated embodiment, the strap 220 extends around the ankle of
the wearer. The location of the limit strap 220 can be varied
depending upon boot design and the types of forces encountered by
the boot in a particular athletic activity.
[0130] For example, in the illustrated embodiment, the limit strap
220 defines an expansion limiting plane which extends generally
horizontally and transverse to the wearer's ankle or lower leg. The
inside diameter or cross section of the footwear thus cannot exceed
a certain value in the expansion limiting plane, despite forces
imparted by the wearer and the otherwise dynamic fit. The
illustrated location tends to limit the dynamic opening of the top
of the boot as the wearer bends forward at the ankle. The function
of the limit strap 220 may be accomplished by one or more straps,
wires, laces or other structures which encircle the ankle, or which
are coupled to other boot components such that the limit strap in
combination with the adjacent boot components provide an expansion
limiting plane. In one embodiment the expansion limiting strap
surrounds the ankle as illustrated in FIG. 5. The anterior aspect
of the strap is provided with an aperture for receiving the reel
assembly therethrough. This allows the use of the expansion
limiting strap in an embodiment having a front mounted reel.
[0131] In an alternative design, the expansion limiting plane is
positioned in a generally vertical orientation, such as by
positioning the limit strap 220 across the top of the foot anterior
of the ankle, to achieve a different limit on dynamic fit. In this
location, the expansion limiting strap 220 may encircle the foot
inside or outside of the adjacent shoe components, or may connect
to the sole or other component of the shoe to provide the same net
force effect as though the strap encircled the foot.
[0132] The limit strap 220 may also create a force limiting plane
which resides at an angle in between the vertical and horizontal
embodiments discussed above, such as in an embodiment where the
force limiting plane inclines upwardly from the posterior to the
anterior within the range of from about 25.degree. to about
75.degree. from the plane on which the sole of the boot resides.
Positioning the limit strap 220 along an inclined force limiting
plane which extends approximately through the ankle can
conveniently provide both a limit on upward movement of the foot
within the boot, as well as provide a controllable limit on the
anterior flexing of the leg at the ankle with respect to the
boot.
[0133] The strap 220 preferably includes a fastener 222 that could
be used to adjust and maintain the tightness of the strap 220.
Preferably, the fastener 222 is capable of quick attachment and
release, so that the wearer can adjust the limit strap 220 without
complication. Any of a variety of fasteners such as corresponding
hook and loop (e.g., Velcro) surfaces, snaps, clamps, cam locks,
laces with knots and the like may be utilized, as will be apparent
to those of skill in the art in view of the disclosure herein.
[0134] The strap 220 is particularly useful in the present
low-friction system. Because the lace 23 slides easily through the
guide members, the tension in the lace may suddenly release if the
lace is severed or the reel fails. This would cause the boot to
suddenly and completely open which could cause injury to the wearer
of the boot, especially if they were involved in an active sport at
the time of failure. This problem is not present in traditional
lacing systems, where the relatively high friction in the lace,
combined with the tendency of the lace to wedge with the
traditional eyelets on the shoe, eliminates the possibility of the
lace suddenly and completely loosening.
[0135] The low-friction characteristics of the present system also
provides the shoe with a dynamic fit around the wearer's foot. The
wearer's foot tends to constantly move and change orientation
during use, especially during active sports. This shifting causes
the tongue and flaps of the shoe to shift in response to the
movement of the foot. This is facilitated by the low-friction
lacing system, which easily equilibrates the tension in the lace in
response to shifting of the wearer's foot. The strap 220 allows the
user to regulate the amount of dynamic fit provided by the boot by
establishing an outer limit on the expansion which would otherwise
have occurred due to the tension balancing automatically
accomplished by the readjustment of the lace throughout the lace
guide system.
[0136] For example, if the wearer of the boot in FIG. 5 did not
have the ankle strap 220, when he flexed his ankle forward during
skating, the increased forward force at the top of the boot would
cause the tongue to move out slightly while the laces lower in the
boot would tighten. As the wearer straightened his ankle out again,
closure force would equalize and the tongue would stay tight
against his ankle. If the strap 220 were wrapped around his ankle
however, it would prevent or reduce this forward movement of the
ankle and tongue reducing the dynamic fit characteristics of the
boot in the plane of the strap 220 and providing a very different
fit and feel of the boot. Thus, the strap provides an effective
means for regulating the amount of dynamic fit inherent in the low
friction closure system. Since traditional lacing systems have so
much friction in them, they do not provide this dynamic fit and
consequently would not benefit from the strap in the same way.
[0137] Similar straps are commonly used in conjunction with
traditional lacing systems but for entirely different reasons. They
are used to provide additional closure force and leverage to
supplement shoelaces but are not needed for safety and are not used
to regulate dynamic fit.
[0138] The footwear lacing system 22 described herein
advantageously allows a user to incrementally tighten the boot 20
around the user's foot. The low friction lace 23 combined with the
low friction guide members 50, 52 produce easy sliding of lace 23
within the guide members 50 and 52. The low friction tongue 36
facilitates opening and closure of the flaps 32 and 34 as the lace
is tightened. The lace 23 equilibrates tension along its length so
that the lacing system 23 provides an even distribution of
tightening pressure across the foot. The tightening pressure may be
incrementally adjusted by turning the knob on the tightening
mechanism 25. A user may quickly untighten the boot 20 by simply
turning or lifting or pressing the knob or operating any
alternative release mechanism to automatically release the lace 23
from the tightening mechanism 25.
[0139] As illustrated in FIG. 6, at least one anti-abrasion member
224 is disposed adjacent the tongue 36 and between the flaps 32,
34. The anti-abrasion member 224 comprises a flat disc-like
structure having a pair of internal channels or lumen 127a,b
arranged in a crossing pattern so as to define a crossing point
230. The lumen 127a,b are sized to receive the lace 23
therethrough. The lumen 127a,b are arranged to prevent contact
between adjacent sections of the lace 23 at the crossing point 230.
The anti-abrasion member 224 thereby prevents chafing of the lace
23 at the crossing point 230. The anti-abrasion member 224 also
shields the lace 23 from the tongue 36 to inhibit the lace 23 from
chafing or abrading the tongue 36.
[0140] The anti-abrasion member 224 may alternatively take the form
of a knife edge or apex for minimizing the contact area between the
lace 23 and the anti-abrasion member 224. For example, at a
crossing point where lace 23 crosses tongue 36, an axially
extending (e.g., along the midline of the foot or ankle) ridge or
edge may be provided in-between the boot tongue 36 and the lace 23.
This anti-abrasion member 224 is preferably molded or otherwise
formed from a lubricious plastic such as PTFE, or other material as
can be determined through routine experimentation. The lace 23
crosses the apex so that crossing friction would be limited to a
small contact area and over a lubricious surface rather than along
the softer tongue material or through the length of a channel or
lumen as in previous embodiments. Tapered sides of the
anti-abrasion member 224 would ensure that the anti-abrasion member
224 stayed reasonably flexible as well as help distribute the
downward load evenly laterally across the foot. The length along
the midline of the foot would vary depending upon the boot design.
It may be as short as one inch long or less and placed on the
tongue just where the one or more lace crossings are, or it may
extend along the entire length of the tongue with the raised ridge
or crossing edge more prominent in the areas where the lace crosses
and less prominent where more flexibility is desired. The
anti-abrasion member 224 may be formed integrally with or attached
to the tongue or could float on top of the tongue as in previously
described disks.
[0141] In one embodiment, the anti-abrasion member 224 is fixedly
mounted on the tongue 36 using any of a wide variety of well known
fasteners, such as rivets, screws, snaps, stitching, glue, etc. In
another embodiment, the anti-abrasion member 224 is not attached to
the tongue 36, but rather freely floats atop the tongue 36 and is
held in place through its engagement with the lace 23.
Alternatively, the anti-abrasion member 224 is integrally formed
with the tongue 36, such as by threading a first portion of the
lace 23 through the tongue, and the second, crossing portion of
lace 23 over the outside surface of the tongue.
[0142] Alternatively, one or more of the sections of lace 23 which
extend between the flaps 32 and 34 may slideably extend through a
tubular protective sleeve. Referring to FIG. 6, three crossover
points are illustrated, each crossover point including a first and
a second crossing segments of the lace 23. A tubular protective
sleeve may be provided on each of the first segments or on both the
first and second segments at each of the crossover points.
Alternatively, the short tubular protective sheaths may be provided
on one or both of the segments of lace 23 at the central crossover
point which, in FIG. 6, is illustrated as carrying the
anti-abrasion member 24. Optimizing the precise number and location
of the protective tubular segments may be routinely accomplished,
by those of skill in the art observing wear patterns of the lacing
system in a particular shoe design.
[0143] The tubular protective element may comprise any of a variety
of tubular structures. Lengths of polymeric or metal tubing may be
utilized. However, such tubular supports generally have a fixed
axial length. Since the distance between the opposing flaps 32 and
34 will vary depending upon the size of the wearer's foot, the
protective tubular sleeves should not be of such a great length
that will inhibit tightening of the lacing system. The tubular
protective sheaths may also have a variable axial length, to
accommodate tightening and loosening of the lacing system. This may
be accomplished, for example, by providing a tubular protective
sheath which includes a slightly stretched spring coil wall. During
tightening of the system, when each of the opposing flaps 32 and 34
are brought towards each other, the axial length of the spring
guide may be compressed to accommodate various sizes. A further
alternative comprises a tubular bellows-like structure having
alternating smaller-diameter and larger-diameter sections, that may
also be axially compressed or stretched to accommodate varying foot
sizes. A variety of specific accordion structures, having pleats or
other folds, will be apparent to those of skill in the art in view
of the disclosure herein. As a further alternative, a telescoping
tubular sleeve may be utilized. In this embodiment, at least a
first tubular sleeve having a first diameter is carried by the lace
23. At least a second tubular sleeve having a second, greater
diameter is also carried by the lace 23. The first tubular sleeve
is axially slideably advanceable within the second tubular sleeve.
Two or three or four or more telescoping tubes may be provided, for
allowing the axial adjustability described above.
[0144] FIG. 7 schematically illustrates a top view of the insole
region of the boot 20. Locking members 232 may be disposed at any
of a wide variety of locations along the lace pathway, such as
locations "b", and "c" to create various lace locking zones. By
alternately locking and unlocking the locking members 232 and
varying the tension in the lace 23, a user may provide zones of
varied tightness along the lace pathway.
[0145] FIG. 8 is a front view of the instep portion of the boot 20.
In the embodiment shown in FIG. 8, the tubular guide members 50 and
52 are mounted directly within the flaps 32, 34, such as within or
between single or multiple layers of material. Preferably, the tips
150 of each of the guide member 50, 52 protrude outwardly from an
inner edge 152 of each of the flaps 32, 34. As best shown in FIG.
9, a set of stitches 154 surrounds each guide member 50 and 52. The
stitches 154 are preferably positioned immediately adjacent the
guide members 50, 52 to create a gap 156 therebetween. For ease of
illustration, the gap 156 is shown having a relatively large size
with respect to the diameter of the guide members 50, 52. However,
the distance between each guide member 50, 52 and the respective
stitches 154 is preferably small.
[0146] Preferably, each set of stitches 154 forms a pattern that
closely matches the shape of the respective guide members so that
the guide members 50, 52 fit snug within the flaps 32, 34. The
stitches 154 thereby inhibit deformation of the guide members 50,
52, particularly the internal radius thereof, when the lace is
tightened. Advantageously, the stitches 154 also function as
anchors that inhibit the guide members 50, 52 from moving or
shifting relative to the flaps 32, 34 during tightening of the
lace.
[0147] The gap 156 may be partially or entirely filled with a
material, such as glue, that is configured to stabilize the
position of the guide members 50, 52 relative to the flaps 32, 34.
The material is selected to further inhibit the guide members 50,
52 from moving within the gap 156. The guide members may also be
equipped with anchoring members, such as tabs of various shape,
that are disposed at various locations thereon and that are
configured to further inhibit the guide members 50, 52 from moving
or deforming relative to the flap 32. The anchoring members may
also comprise notches or grooves on the guide members 50, 52 that
generate friction when the guide members 50, 52 begin to move and
thereby inhibit further movement. The grooves may be formed using
various methods, such as sanding, sandblasting, etching, etc. Axial
movement of the guide tubes 50 or 52 may also be limited through
the use of any of a variety of guide tube stops (not shown). The
guide tube stop includes a tubular body having an opening which
provides access to a central lumen extending therethrough. The stop
may also be provided with one or more fastening tabs for sewing or
gluing to the shoe, as has been discussed. Tabs, once stitched or
otherwise secured into place, resist axial movement of the device
along its longitudinal pathway.
[0148] With reference to FIGS. 10 and 11, an alternative guide
member 250 comprises a thin, single-piece structure having an
internal lumen 252 for passage of the lace 23 therethrough. The
guide member 250 includes a main portion 254 that defines a
substantially straight inner edge 256 of the guide member. A flange
portion 260 extends peripherally around one side of the main
portion 254. The flange portion 260 comprises a region of reduced
thickness with respect to the main portion 254. An elongate slot
265 comprised of a second region of reduced thickness is located on
the upper surface 266a of the guide member 250.
[0149] A pair of lace exit holes 262 extend through a side surface
of the lace guide member 250 and communicate with the lumen 252.
The lace exit holes 262 may have an oblong shape to allow the lace
23 to exit therefrom at a variety of exit angles.
[0150] With reference to FIGS. 10 and 11, a series of upper and
lower channels 264a, 264b, respectively, extend through upper and
lower surfaces 266a, 266b, respectively, of the lace guide member
250. The channels 264 are arranged to extend along the pathway of
the lumen 252 and communicate therewith. The location of each of
the upper channels 264a preferably successively alternates with the
location of each of the lower channels 264b along the lumen pathway
so that the upper channels 264a are offset with respect to the
lower channels 264b.
[0151] With respect to FIGS. 12 and 13, the lace guide member 250
is mounted to the flaps 32, 34 by inserting the flange region 260
directly within the flaps 32, 34, such as within or between single
or multiple layers 255 (FIG. 13) of material. The layers 255 may be
filled with a filler material 257 to maintain a constant thickness
in the flaps 32, 34.
[0152] The lace guide member 250 may be secured to the flaps 32,
34, for example, by stitching a thread through the flap 32, 34 and
through the lace guide member 250 to form a stitch pattern 251. The
thread is preferably stitched through the reduced thickness regions
of the flange portion 260 and the elongate slot 265. Preferably,
the flaps 32, 34 are cut so that the main portion 254 of the guide
member 250 is exposed on the flap 32, 34 when the lace guide member
250 is mounted thereon.
[0153] With respect to FIG. 13, the upper surface 266a of the main
portion of the guide member 250 is preferably maintained flush with
the upper surface of the flaps 32, 34 to maintain a smooth and
continuous appearance and to eliminate discontinuities on the flaps
32, 34. Advantageously, because the flange region 260 has a reduced
thickness, the lace guide member 250 is configured to provide very
little increase in the thickness of the flaps 32, 34, and
preferably no increase in the thickness of the flaps. The lace
guide member 250 therefore does not create any lumps in the flaps
32, 34 when the guide member 250 is mounted therein.
[0154] As mentioned, a series of upper and lower offset channels
264a,b extend through the lace guide member 250 and communicate
with the lumen 252. The offset arrangement of the channels
advantageously facilitates manufacturing of the guide members 250
as a single structure, such as by using shut-offs in an injection
mold process.
[0155] The shape of the lumen may be approximately defined by an
ellipse. In one embodiment, the ellipse has a major axis of about
0.970 inches and a minor axis of about 0.351 inches.
[0156] FIG. 14 is a side view of an alternative tightening
mechanism 270. The tightening mechanism 270 includes an outer
housing 272 having a control mechanism, such as a rotatable knob
274, mechanically coupled thereto. The rotatable knob 274 is
slideably movable along an axis A between two positions with
respect to the outer housing 272. In a first, or engaged, position,
the knob 274 is mechanically engaged with an internal gear
mechanism located within the outer housing 272. In a second, or
disengaged, position (shown in phantom) the knob is disposed
upwardly with respect to the first position and is mechanically
disengaged from the gear mechanism. The tightening mechanism 270
may be removably mounted to the front, back, top or sides of the
boot.
[0157] The closure system includes a rotatable spool for receiving
a lace. The spool is rotatable in a first direction to take up lace
and a second direction to release lace. A knob is connected to the
spool such that the spool can be rotated in the first direction to
take up lace only in response to rotation of the knob. A releasable
lock is provided for preventing rotation of the spool in the second
direction. One convenient lock mechanism is released by pulling the
knob axially away from the boot, thereby enabling the spool to
rotate in the second direction to unwind lace. However, the spool
rotates in the second direction only in response to traction on the
lace. The spool is not rotatable in the second direction in
response to rotation of the knob. This prevents tangling of the
lace in or around the spool, which could occur if reverse rotation
on the knob could cause the lace to loosen in the absence of a
commensurate traction on the lace.
[0158] In the foregoing embodiments, the wearer must pull a
sufficient length of cable from the spool to enable the wearer's
foot to enter or exit the footwear. The resulting slack cable
requires a number of turns of the reel to wind in before the boot
begins to tighten. An optional feature in accordance with the
present invention is the provision of a spring drive or bias within
the spool that automatically winds in the slack cable, similar to
the mechanism in a self biased automatically winding tape measure.
The spring bias in the spool is generally not sufficiently strong
to tighten the boot but is sufficient to wind in the slack. The
wearer would then engage the knob and manually tighten the system
to the desired tension.
[0159] The self winding spring may also be utilized to limit the
amount of cable which can be accepted by the spool. This may be
accomplished by calibrating the length of the spring so that
following engagement of the knob and tightening of the boot, the
knob can only be rotated a preset additional number of turns before
the spring bottoms out and the knob is no longer able to be turned.
This limits how much lace cable could be wound onto the spool.
Without a limit such as this, if a cable is used which is too long,
the wearer may accidentally wind in the lace cable until it jams
tightly against the reel housing and cannot be pulled back out.
[0160] FIGS. 21-27 illustrate one embodiment of a lace winder 600
including a spring configured to automatically eliminate loose
slack in the laces 23 by maintaining the laces 23 under tension. In
the illustrated embodiments, the winder 600 generally comprises a
spool 610 rotatably positioned within a housing member 620 and
rotationally biased in a winding direction. The spool 610 is also
generally coupled to a knob 622 for manually tightening the laces
23. Many features of the winder 600 of FIGS. 21-27 are
substantially similar to the tightening mechanism 270 discussed
above with reference to FIG. 14. However, in alternative
embodiments, features of the spring-biased winder 600 can be
applied to many other tightening mechanisms as desired.
[0161] FIG. 21 illustrates an exploded view of one embodiment of a
lace winder 600. The embodiment of FIG. 21 illustrates a spring
assembly 630, a spool assembly 632 and a knob assembly 634. The
spool assembly 632 and the spring assembly 630 are generally
configured to be assembled to one another and placed within a
housing 640. The knob assembly 634 can then be assembled with the
housing 640 to provide a self-winding lacing device 600.
[0162] The knob assembly 634 generally comprises a knob 622 and a
drive gear 642 configured to rotationally couple the knob 622 to a
drive shaft 644 which extends through substantially the entire
winder 600. In alternative embodiments, the knob assembly 634 can
include any of the other devices described above, or any other
suitable one-way rotating device.
[0163] With reference to FIGS. 23-26, in some embodiments, the
housing 640 generally comprises an upper section with a plurality
of ratchet teeth 646 configured to engage pawls 648 in to the knob
622 (see FIG. 22). The housing 640 also includes a spool cavity 650
sized and configured to receive the spool assembly 632 and spring
assembly 630 therein. A lower portion of the spool cavity 650
generally comprises a plurality of teeth forming a ring gear 652
configured to engage planetary gears 654 of the spool assembly
632.
[0164] A transverse surface 656 generally separates the upper
portion of the housing 640 from the spool cavity 650. A central
aperture 658 in the transverse surface allows the drive shaft 644
to extend from the knob 622, through the housing 640 and through
the spool assembly 632. In some embodiments, set-screw apertures
660 and/or a winding pin aperture 662 can also extend through the
housing 640 as will be further described below. The housing 640
also typically includes a pair of lace entry holes 664 through
which laces can extend.
[0165] As discussed above, a gear train can be provided between the
knob 622 and the spool 610 in order to allow a user to apply an
torsional force to a spool 610 that is greater than the force
applied to the knob. In the embodiment of FIGS. 21-25, such a gear
train is provided in the form of an epicyclic gear set including a
sun gear 670 and a plurality of planetary gears 654 attached to the
spool 610, and a ring gear 650 on an internal surface of the
housing 640. The illustrated epicyclic gear train will cause a
clockwise rotation of the drive shaft 644 relative to the housing
640 to result in a clockwise rotation of the spool 610 relative to
the housing 640, but at a much slower rate, and with a much
increased torque. This provides a user with a substantial
mechanical advantage in tightening footwear laces using the
illustrated device. In the illustrated embodiment, the epicyclic
gear train provides a gear ratio of 1:4. In alternative
embodiments, other ratios can also be used as desired. For example,
gear ratios of anywhere from 1:1 to 1:5 or more could be used in
connection with a footwear lace tightening mechanism.
[0166] With reference to FIGS. 21, 23 and 25, embodiments of a
spool assembly 632 will now be described. The spool assembly 632
generally comprises a spool body 610, a drive shaft 644, a sun gear
670, a plurality of planetary gears 654, a pair of set screws 672
and a bushing 674. The spool body 610 generally comprises a central
aperture 676, a pair of set screw holes 678, a winding section 680
and a transmission section 682. The winding section 680 comprises a
pair of lace receiving holes 684 for receiving lace ends which can
be secured to the spool using set screws 672 or other means as
described in previous embodiments. The lace receiving holes 684 are
generally configured to be alignable with the lace entry holes 664
of the housing 640. In some embodiments, the spool body 610 also
comprises a winding pin hole 690 configured to receive a winding
pin for use in assembling the winder 600 as will be further
described below. In some embodiments, the spool 610 can also
include sight holes 692 to allow a user to visually verify that a
lace 23 has been inserted a sufficient distance into the spool 610
without the need for markings on the lace 23.
[0167] The bushing 674 comprises an outer diameter that is slightly
smaller than the inner diameter of the spool central aperture 676.
The bushing 674 also comprises an inner aperture 694 configured to
engage the drive shaft 644 such that the bushing 674 remains
rotationally stationary relative to the drive shaft throughout
operation of the device. In the illustrated embodiment, the drive
shaft 644 comprises an hexagonal shape, and the bushing 674
comprises a corresponding hexagonal shape. In the illustrated
embodiment, the sun gear 670 also comprises an hexagonal aperture
702 configured to rotationally couple the sun gear 670 to the drive
shaft 644. Alternatively or in addition, the sun gear 670 and/or
the bushing 674 can be secured to the drive shaft 644 by a press
fit, keys, set screws, adhesives, or other suitable means. In other
embodiments, the drive shaft 644, bushing 674 and/or sun gear 670
can comprise other cross-sectional shapes for rotationally coupling
the elements.
[0168] In an assembled condition, the bushing 674 is positioned
within the spool aperture 676, the drive shaft 644 extends through
the central aperture 694 of the bushing 674 and through the sun
gear 670. In some embodiments, the planetary gears 654 can be
secured to axles 704 rigidly mounted to the transmission section
682 of the spool 610. The planetary gears 654, when assembled on
the spool 610, generally extend radially outwards from the
perimeter of the spool 610 such that they may engage the ring gear
652 in the housing 640. In some embodiments, the spool transmission
section 682 comprises walls 706 with apertures located to allow the
planetary gears 654 to extend therethrough. If desired, a plate 710
can be positioned between the planetary gears 654 and the spring
assembly 630 in order to prevent interference between the moving
parts.
[0169] The spring assembly 630 generally comprises a coil spring
712, a spring boss 714, and a backing plate 716. In some
embodiments, a washer/plate 718 can also be provided within the
spring assembly 630 between the coil spring 718 and the spring boss
714 in order to prevent the spring 712 from undesirably hanging up
on any protrusions of the spring boss 714.
[0170] With particular reference to FIG. 27, in some embodiments,
the spring boss 714 is rigidly joined to the backplate 716 and the
torsional spring 712 is configured to engage the spring boss 714 in
at least one rotational direction. The coil spring 712 generally
comprises an outer end 720 located at a periphery of the spring
712, and an inner end 722 at a central portion of the spring 712.
The outer end 720 is generally configured to engage a portion of
the spool 610. In the illustrated embodiment, the outer end 720
comprises a necked-down portion to engage an aperture in a portion
of the spool 610. In alternative embodiments, the outer end 720 of
the spring 712 can be secured to the spool by welds, mechanical
fasteners, adhesives or any other desired method. The inner end 722
of the spring 712 comprises a hooked portion configured to engage
the spring boss 714.
[0171] The spring boss 714 comprises a pair of posts 730 extending
upwards from the backplate 716. The posts 730 are generally
crescent shaped and configured to engage the hooked interior end
722 of the spring 712 in only one rotational direction. Each post
730 comprises a curved end 736 configured to receive the hooked
spring end 722 as the spring rotates counter-clockwise relative to
the backplate 716. Each post 730 also comprises a flat end 738
configured to deflect the hooked spring end 722 as the spring 712
rotates clockwise relative to the backplate 716. In the illustrated
embodiment, the posts 714 and spring 712 are oriented such that a
clockwise rotation of the spring 712 relative to the spring boss
714 and backplate 716 will allow the spring to "skip" from one post
714 to the other without resisting such rotation. On the other
hand, a counter-clockwise rotation of the spring 712 will cause the
hooked end 722 to engage one of the posts 714, thereby holding the
interior end 722 of the spring stationary relative to the outer
portions of the spring 712. Continued rotation of the outer
portions of the spring will deflect the spring, thereby biasing it
in the clockwise winding direction.
[0172] The space 732 between the posts 730 of the spring boss 714
is generally sized and configured to receive the distal end of the
drive shaft, which in some embodiments as shown in FIG. 21, can
comprises a circular end 734 configured to freely rotate in the
spring boss space 732. In the embodiment illustrated in FIG. 21,
the spring boss 714 and the backplate 716 are shown as separately
manufactured elements which are later assembled. In alternative
embodiments, the backplate 716 and spring boss 714 can be
integrally formed as a unitary structure and/or as portions of
another structure.
[0173] Embodiments of methods for assembling a self-coiling lace
winder 600 will now be described with reference to FIGS. 21-26. In
one embodiment, the sun and planetary gears 670, 654 are assembled
onto the transmission portion 682 of the spool 610, and the bushing
674 and drive shaft 644 are inserted through the aperture 676 in
the spool. The spring assembly 630 is assembled by attaching the
spring boss 714 to the back plate 716 by any suitable method and
placing the spring 712 on the spring boss 714. The spool assembly
632 can then be joined to the spring assembly 630 by attaching the
outer end 720 of the spring 712 to the spool 610. In some
embodiments, the spring 712 may need to be pre-wound tightly in
order to fit within the spool walls 706. The spool assembly 632 and
the spring assembly 630 can then be placed within the housing
member 640. In some embodiments, the backplate 716 is secured to
the housing member 640 by screws 740 or other suitable fasteners
such as rivets, welds, adhesives, etc. In some embodiments, the
backplate 716 can include notches 742 configured to cooperate with
extensions or recesses in the housing member 640 in order to
prevent the entirety of the torsional spring load from bearing
against the screws 740.
[0174] In some embodiments, once the spool assembly 632 and the
spring assembly 630 are assembled and placed in the housing 640,
the spring 712 can be tensioned prior to attaching the laces. In
one embodiment, with reference to FIG. 26, the spring 712 is
tensioned by holding the housing 640 stationary and rotating the
drive shaft 644 in an unwinding direction 740, thereby increasing
the deflection in the spring 712 and correspondingly increasing a
biasing force of the spring. Once a desired degree of
deflection/spring bias is reached, a winding pin 742 can be
inserted through the winding pin aperture 662 in the housing 640
and the winding pin hole 690 in the spool 610.
[0175] In one embodiment, the winding pin hole 690 in the spool is
aligned relative to the winding pin aperture 662 in the housing
such that the set screw holes 678 and the lacing sight holes 692 in
the spool 610 will be aligned with corresponding apertures 660 in
the housing 640 when the winding pin 742 is inserted (also see FIG.
25). The spool 610 and housing 640 are also preferably configured
such that the lace receiving holes 684 of the spool 610 are aligned
with the lace entry holes 664 of the housing 640 when the winding
pin hole 690 and aperture 662 are aligned. In alternative
embodiments, the winding pin hole 690 and aperture 662 can be
omitted, and the spool can be held in place relative to the housing
by some other means, such as by placing a winding pin 742 can be
inserted through a set screw hole and aperture or a sight
hole/aperture.
[0176] Once the spring 712 has been tensioned and a winding pin 742
has been inserted, the laces 23 can be installed in the spool using
any suitable means provided. In the embodiment illustrated in the
embodiments of FIGS. 21-26, the spool 610 is configured to secure
the laces 23 therein with set screws 672. The laces can be inserted
through the lace entry holes 664 in the housing 640 and through the
lace receiving holes 684 in the spool 610 until a user sees the end
of the lace in the appropriate sight hole 692. Once the user
visually verifies that the lace is inserted a sufficient distance,
the set screws 672 can be tightened, thereby securing the laces in
the spool.
[0177] Once the laces 23 are secured, the winding pin 742 can be
removed, thereby allowing the spring to wind up any slack in the
laces. The knob 622 can then be attached to the housing 640, such
as by securing a screw 750 to the drive shaft 644. A user can then
tighten the laces 23 using the knob 622 as desired.
[0178] In alternative embodiments, it may be desirable to
pre-tension the spring 712 after installing the laces 23 in the
spool 610. For example, if an end user desires to change the laces
in his/her footwear, the old laces 23 can be removed by removing
the knob 622, loosening the set screws 672 and pulling out the
laces 23. New laces can then be inserted through the lace entry
holes 684 and secured to the spool with the set screws 672, and
re-install the knob 622 as described above. In order to tension the
spring 712, a user can then simply wind the lace by rotating the
knob 622 in the winding direction until the laces are fully
tightened (typically without a foot in the footwear). The spring
will not resist such forward winding, since the spring boss 714
will allow the spring 712 to freely rotate in the forward direction
as described above. In one preferred embodiment, the user tightens
the laces as much as possible without a foot in the footwear. Once
the laces are fully tightened, the knob can be released, such as by
pulling outwards on the knob as described above, and the laces can
be pulled out. As the spool rotates in an unwinding direction, the
hooked inner end 722 of the spring 712 engages the spring boss 714,
and the spring deflects, thereby again biasing the spool 610 in a
winding direction.
[0179] In an alternative embodiment, a lace winder can be
particularly useful for lightweight running shoes which do not
require the laces to be very tight. Some existing lightweight
running shoes employ elastic laces, however such systems are
difficult, if not impossible, to lock once a desired lace tension
is achieved. Thus, an embodiment of a lightweight spring-biased
automatically winding lacing device can be provided by eliminating
the knob assembly 634, gears 654, 670 and other components
associated with the manual tightening mechanism. In such an
embodiment, the spool 610 can be greatly simplified by eliminating
the transmission section 682, the housing 640 can be substantially
reduced in size and complexity by eliminating the ring gear section
652 and the ratchet teeth 646. A simplified spool can then be
directly connected to a spring assembly 630, and a simple locking
mechanism can be provided to prevent unwinding of the laces during
walking or running.
[0180] Therefore, a right reel and a left reel can be configured
for opposite directional rotation to allow a user to more naturally
grip and manipulate the reel. It is currently believed that an
overhand motion, e.g. a clockwise rotation with a person's right
hand, is a more natural motion and can provide a greater torque to
tighten the reel. Therefore, by configuring a right and left reel
for opposite rotation, each reel is configured to be tightened with
an overhand motion by tightening the right reel with the right
hand, and tightening the left reel with the left hand.
[0181] Alternatively, the guide members 490 may comprise a lace
guide defining an open channel having, for example, a semicircular,
"C" shaped, or "U" shaped cross section. The guide member 490 is
preferably mounted on the boot or shoe such that the channel
opening faces away from the midline of the boot, so that a lace
under tension will be retained therein. One or more retention
strips, stitches or flaps may be provided for "closing" the channel
opening to prevent the lace from escaping when tension on the lace
is released. The axial length of the channel can be preformed in a
generally U configuration. Moreover, practically any axial
configuration of the guide member 490 is possible, and is mainly
dictated by fashion, and only partly by function.
[0182] Several guide members 490 may be molded as a single piece,
such as several lace guides 491 molded to a common backing support
strip which can be adhered or stitched to the shoe. Thus, a right
lace guide member and a left lace guide member can be secured to
opposing portions of the top or sides of the shoe to provide a
right set of guide channels 492 and a left set of guide channels
492. When referring to "right" and "left" guide members, this
should not be construed as suggesting a mounting location of the
retainer strips. For example, the guide members 490 can be located
on a single side of the shoe, such as in a shoe having a vamp that
extends generally from one side of the shoe, across the midline of
the foot, and is secured by laces on the opposing side of the shoe.
In this type of shoe, the guide members 490 are actually disposed
vertically with respect to one another, and hence, a left and right
guide member merely refers to the fact that the guide members 490
have openings that face one another, as illustrated in FIG. 16.
[0183] FIGS. 15 and 16 illustrate exemplary embodiments and
mounting configurations of the present footwear-lacing system. For
example, a plurality of guide members 490 can be located in lieu of
traditional shoe eyelet strips, as described above. Typically, the
guide members 490 are installed as opposing pairs, with the guide
members formed integrally with the reel 498 typically comprising
one of the guide members. The term "reel" will be used hereinafter
to refer to the various embodiments including the complete
structure of the outer housing and its internal components, unless
otherwise specified. Thus, in some embodiments, there are 2, 4, 6,
or 8 or more cooperating guide members 490 installed to define a
lace path. Moreover, a non-paired guide member 490 can be
installed, such as toward the toe of the shoe and positioned
transverse to the midline and having its lace openings directed
toward the heel of the shoe. This configuration, in addition to
applying tightening forces between the lateral and medial sides of
the shoe, would also apply a lace tension force along the midline
of the shoe. Of course, other numbers and arrangements of guide
members can be provided and this application and its claims should
not be limited to only configurations utilizing opposing or even
paired guide members.
[0184] FIG. 15 shows an embodiment in which the reel 498 is located
on the lateral quarter panel of the shoe. Of course, the reel 498
can be located practically anywhere on the shoe and only some of
the preferred locations are described herein. Moreover, the
illustrated reel can be any reel embodiment suitable for practicing
the present invention, and should not be limited to one particular
embodiment. The illustrated embodiment provides three guide members
490 spaced along the gap between the medial quarter panel 500 and
lateral quarter panels 502 of the shoe and thus creates a lace path
that zigzags across the tongue 504. While the reel 498 is
illustrated as being disposed on the lateral quarter 502 panel near
the ankle, it may also be disposed on the medial quarter panel 500
of the shoe. In some embodiments, the reel 498 is disposed on the
same quarter panel of each shoe, for example, the reel can be
mounted on the lateral quarter panel 502 of each shoe, or in
alternative embodiments, the reel can be disposed on the lateral
quarter panel 502 of one shoe, and on the medial quarter panel 500
of the other shoe.
[0185] Notably, this particular embodiment has a lace path that
forms an acute angle a as it enters the outer housing. As discussed
above, a lace guide member can be integrally formed into the outer
housing to direct the lace to approach and interact with the reel
from substantially diametrical directions. Thus, the summation of
tension forces applied to the reel are substantially cancelled.
[0186] FIG. 17 shows an alternative embodiment of a shoe
incorporating a vamp closure structure. In this particular
embodiment, the reel 498 can be disposed on the vamp 506, as
illustrated, or can be disposed on the lateral quarter panel, or
even in the heel, as disclosed above. Similar to FIG. 15, the reel
illustrated in this FIG. 16 should not be limited to one specific
embodiment, but should be understood to be any suitable embodiment
of a reel for use with the disclosed invention. In the illustrated
embodiment, three lace guides 490 are affixed to the shoe; two on
the lateral quarter panel 502, and one on the vamp 506 cooperating
with the guide members integrally formed with the reel 498 to
define a lace path between the lateral quarter panel 502 and the
vamp 506. Those of ordinary skill will appreciate that the guide
members can be spaced appropriately to result in various tightening
strategies.
[0187] For example, the opposing guide members 490 can be spaced a
greater distance apart to allow a greater range of tightening. More
specifically, by further separating the opposing guide members 490,
there is a greater distance that can be used to effectuate
tightening before the guide members 490 bottom out. This embodiment
offers the additional advantage of extending the lace 23 over a
substantially planar portion of the shoe, rather than across a
portion of the shoe having a convex curvature thereto.
[0188] FIG. 17 illustrates an alternative arrangement of a shoe
incorporating a vamp closing structure and having a reel and a
non-looping lace. In this particular embodiment, an open ended lace
can be attached directly to a portion of the shoe. As illustrated,
a reel 498 is mounted on the lateral quarter panel 502 of the shoe.
The shoe has one or more lace guides 490 strategically positioned
thereon. As illustrated, one lace guide 490 is mounted on the vamp
506 while a second lace guide 498 is mounted on the lateral quarter
panel 502. A lace has one end connected to a spool within the reel
498 and extends from the reel 498, through the lace guides 490 and
is attached directly to the shoe by any suitable connection 512.
One suitable location for attaching the lace is on the vamp toward
the toe for those embodiments in which the reel 498 is mounted on
the lateral quarter panel 502.
[0189] The connection 512 may be a permanent connection or may be
releasable to allow the lace to be removed and replaced as
necessary. The connection is preferably a suitable releasable
mechanical connection, such as a clip, clamp, or screw, for
example. Other types of mechanical connections, adhesive bonding,
or chemical bonding may also be used to attach a lace end to the
shoe.
[0190] While the illustrated embodiment shows the reel 498 attached
to the lateral quarter panel 502, it should be apparent that the
reel 498 could readily be attached to the vamp 506 and still
provide the beneficial features disclosed herein. Additionally, the
lace could optionally be attached to the shoe on the lateral
quarter panel 502 rather than the vamp 506. The reel 498 and lace
could be attached to a common portion of the shoe, or may be
attached to different portions of the shoe, as illustrated. In any
case, as the lace is tightened around the spool, the lace tension
draws the guide members toward each other and tightens the footwear
around a wearer's foot.
[0191] A shoe is typically curved across the midline to accommodate
the dorsal anatomy of a human foot. Therefore, in an embodiment in
which the laces zigzag across the midline of the shoe, the further
the lace guides 490 are spaced, the closer the laces 23 are to the
sole 510 of the shoe. Consequently, as the laces 23 tighten, a
straight line between the lace guides 490 is obstructed by the
midline of the shoe, which can result in a substantial pressure to
the tongue of the shoe and further result in discomfort to the
wearer and increased chaffing and wearing of the tongue. Therefore,
by locating the laces 23 across a substantially flat surface on
either the lateral or medial portion of the shoe, as illustrated,
the laces 23 can be increasingly tightened without imparting
pressure to other portions of the shoe.
[0192] It is contemplated that some embodiments of the lacing
system 22 discussed herein will be incorporated into athletic
footwear and other sports gear that is prone to impact. Such
examples include bicycle shoes, ski or snowboard boots, and
protective athletic equipment, among others. Accordingly, it is
preferable to protect the reel from inadvertent releasing of the
spool and lace by impact with external objects.
[0193] FIGS. 18 and 19 illustrate a lacing system 22 further having
a protective element to protect the reel from impact from external
objects. In one embodiment, the protective element is a shield 514
comprised of one or more raised ridges 516 or ramps configured to
extend away from the mounting flange 406 a distance sufficiently
high to protect the otherwise exposed reel. In the illustrated
embodiment, the shield 514 is configured to slope toward the reel
thus presenting an oblique surface to any objects it may contact to
deflect the objects away from the reel. The shield 514 is
positioned around the reel circumferentially and slopes radially
toward the reel and may encircle the reel, or may be positioned
around half the reel, a quarter of the reel, or any suitable
portion or portions of the reel.
[0194] The shield 514 may be integrally formed with the mounting
flange 406, such as during molding, or may be formed as a separate
piece and subsequently attached to the lacing system 22 such as by
adhesives or other suitable bonding techniques. It is preferable
that the shield 514 is formed of a material exhibiting a sufficient
hardness to withstand repeated impacts without plastically
deforming or showing undue signs of wear.
[0195] Another embodiment of a protective element is shown in FIG.
20. In this embodiment, a shield 514 is in the form of a raised lip
517 that encircles a portion of the circumference of the knob (not
shown). The lip 517 can be of sufficient height to exceed the top
of the knob, or can extend to just below the height of the knob to
allow a user to still grasp the knob above the lip 517, or the lip
517 can be formed with varying heights. The lip 517 is preferably
designed to withstand impact from various objects to thereby
protect the knob from being inadvertently rotated and/or displaced
axially.
[0196] The lip 517 can be integrally molded with the mounting
flange, or can be a separate piece. In addition, the lip 517 can
take on various shapes and dimensions to satisfy aesthetic tastes
while still providing the protective function it has been designed
for. For example, it can be formed with various draft angles,
heights, bottom fillets, of varying materials and the like. In the
illustrated embodiment, the lip 517 extends substantially around
the entire circumference of the knob 498, except at holds 521 where
the lip 517 recedes sufficiently to allow a user to grasp a large
portion of the knob's height to be able to displace the knob
axially by lifting it away from the housing. The illustrated
embodiment additionally shows that the lip 517 extends outward to
protect a substantial portion of the knob's height. While the lip
517 is illustrated as extending around a particular portion of the
knob's circumference, it can of course extend around more or less
of the knob's circumference. Certain preferred embodiments
integrate a continuous shield 514 extending around between a
quarter and a half of the knob circumference, while other
embodiments incorporate a shield 514 comprising one or more
discrete portions that combine to cover any appropriate range about
the circumference of the knob. Of course, other protective elements
or shields 514 could be incorporated to protect the reel, such as a
protective covering or cap to cover the reel, a cage structure that
fits over the reel, and the like.
[0197] FIGS. 28-30D illustrate an embodiment of an alternative
lacing arrangement which is generally configured to provide a
plurality of lace tightening zones for an item of footwear. Such a
multi-zone lacing system can provide substantial benefits by
allowing a user to independently tighten various different sections
of a footwear item to various different tensions. For example, in
many cases, it may be desirable to tighten a toe portion more than
an upper portion. In other cases, a user may desire the opposite, a
tight upper and a looser toe section. However, in either case,
users typically want a strong heel-hold-down force at an ankle
portion of the footwear. Thus, in addition to providing multiple
independent lacing zones, the systems illustrated in FIGS. 28-30
are also advantageously arranged to hold the ankle section of a
footwear item under the tension of the tighter of the two
laces.
[0198] FIG. 28 is a schematic illustration of one embodiment of
multi-zone lacing system 800. The system of FIG. 28 includes first
802 and second 804 lace tightening mechanisms arranged to tighten
first 23a and second 23b laces. In some embodiments, the first
tightening mechanism 802 may be located on a tongue, while the
second 804 may be located on a side of a boot. Alternatively, both
of the tightening mechanisms 802, 804 can be provided on a tongue
or on a side of the footwear. In alternative embodiments, the
mechanisms can be otherwise located on a footwear item. In further
alternative embodiments, a multi-zone lacing system can be provided
with a single lace tightening device comprising a plurality of
individually operable spools. Such individually operable spools can
be operated by a single knob and a selector mechanism, or each
spool can include its own knob.
[0199] One embodiment of multi-zone lacing system 800 is preferably
a dual loop tightening system in which a first tightening loop has
a first lace 23a having a first length and a second tightening loop
has a second lace 23b having a second length. In some embodiments,
first lace 23a and second lace 23b have equal lengths. In other
embodiments, the length of second lace 23b is preferably in the
range of from about 100% to about 150% of the length of first lace
23a. In some embodiments, the length of second lace 23b is
preferably at least 110% of the length of first lace 23a. In still
other embodiments, the length of second lace 23b is preferably at
least 125% of the length of first lace 23a. In alternative
embodiments, the lengths of first 23a and second 23b laces are
reversed. First loop preferably has a lock 802 such as a reel
located on a tongue of the footwear and second loop has a lock 804
such as a reel on the side or rear of the footwear. Alternatively,
locks 802, 804 may be located elsewhere on the footwear, including
both located on a tongue or both on the sides or rear of the
footwear.
[0200] The multi-zone lacing system 800 schematically shown in FIG.
28 is a triple-zone lacing system. Each zone is generally defined
by a pair of lateral lace guides which will be drawn towards one
another generally along a line between their centers. Thus, the
first lacing zone 810 is defined by the first lace 23a extending
between first 812 and second 814 lace guides. A second lacing zone
820 is defined by the second lace 23b extending between third 822
and fourth 824 lace guides, and a third lacing zone 830 is defined
by the region between the fifth 832 and sixth 834 lace guides,
through which both the first and second laces 23a, 23b extend. In
alternative embodiments, multi-zone lacing systems can be provided
with only two zones, or with four or more zones, and each zone can
comprise any number of overlapping laces as desired.
[0201] In the embodiment of FIG. 28, the third lacing zone 830 in
which the laces overlap provides the unique advantage of
automatically tightening the third zone 830 according to the
tighter of the two laces 23a, 23b. In one embodiment, the third
lacing zone 830 coincides with an ankle portion of a footwear item.
In this embodiment, the third lacing zone advantageously lies along
an ankle plane which can extends through a pivot axis of a wearer's
ankle at an angle of anywhere from zero to 90 degrees relative to a
horizontal plane. In some embodiments, the third zone lies in a
plane at between about 30 and about 75 degrees relative to a
horizontal plane. In one embodiment, the ankle plane lies at an
angle of about 45.degree. above a horizontal plane. In alternative
embodiments, the third lacing zone 830 lies along a plane passing
through a rear-most point of a wearer's heel and the ankle pivot
axis. By locating the third lacing zone along the ankle plane, a
wearer's heel can be held tightly in the footwear regardless of
which lace is tighter.
[0202] As shown in FIG. 28, the multizone lacing system 800 employs
a plurality of lace guides of various types. For example, an upper
section of the first lace 23a and a lower section of the second
lace 23b are shown extending through first 812, and second 814,
third 822 and fourth curved lace guides 824 respectively. Each of
the curved lace guides 812, 814, 822, 824 comprises a guide section
842 for substantially frictionless engagement with the laces 23 and
an attachment section 844 for securing the lace guide to respective
flaps of a footwear item. In some embodiments, the curved lace
guides 812, 814, 822, 824 can be similar to the guides 250
described above with reference to FIGS. 10-13.
[0203] Central abrasion preventing guides 846, 848 can also be
provided between lateral pairs of lace guides to prevent the laces
from abrading one another and to keep the laces from tangling with
one another. In alternative embodiments, any of the lace guides in
the multi-zone lacing system of FIG. 28 can be replaced by any
other suitable lace guides as described elsewhere herein. The lace
guides can be injection molded or otherwise formed from any
suitable material, such as nylon, PVC or PET. As discussed
elsewhere herein, lace guides are generally configured to draw
opposite flaps of a footwear item towards one another in order to
tighten the footwear. This is generally accomplished by providing a
guide with a minimum of friction or abrasion-causing surfaces.
[0204] In the illustrated embodiment, the third lacing zone
advantageously employs a pair of "double-decker" lace guides 832,
834 configured to guide both the first lace and the second lace
along an overlapping path while holding the laces 23a, 23b apart in
order to prevent their abrading one another. The lower section of
the first lace 23a, and a portion of the second lace 23b are shown
extending through a double-decker lace guide 834 and a
double-decker pass-through lace guide 832. FIGS. 29A-29D illustrate
an embodiment of a double-decker lace guide for use in embodiments
of a multi-zone lacing system. The double-decker lace guide 834
generally comprises an upper lace guiding section 850 for guiding
the first lace 23a, a lower lace guiding section 852 for guiding
the second lace 23b, and an attachment section 844 for securing the
guide to the footwear. In the illustrated embodiment, each of the
upper and lower guide sections 850, 852 comprise arcuate surfaces
configured to guide the laces 23 in a substantially frictionless
manner. Each of the arcuate sections can be similar to the guides
described above with reference to FIGS. 10-13.
[0205] FIGS. 30A-30D illustrate one embodiment of a double-decker
pass-through lace guide 832. The pass-through guide 832 comprises
an upper arcuate section 860 configured to guide the first lace
23a, and a lower pass-through section 862. The upper guide section
860 is preferably separated from the lower pass-through section in
order to prevent the first 23a and second 23b laces from abrading
one another. The lower pass-through section 862 is generally
configured to receive a section of axially-incompressible tubing
864 which abuts a transverse surface 866 of the guide 832. The
transverse surface 866 also includes holes 868 sized to allow the
lace 23b to pass therethrough, while retaining the tubing on one
side of the surface 866. The tubing 864 can be any suitable type,
such as a bicycle cable sheath or other material as described
elsewhere herein. The incompressible tubing sections 864 are
provided over the sections of the second lace 23b between the lower
section 862 of the double-decker pass-through guide 832 and the
lace tightening mechanism 804. This prevents the guide 832 from
being drawn towards the tightening mechanism 804 as the lace is
tightened, and insures that the tightening force is only applied to
drawing the flaps of the footwear towards one another. In an
alternative embodiment, the tubing sections 864 can be eliminated
by incorporating the tightening mechanism into a lace guide in the
position of the pass-through guide 832.
[0206] In some embodiments, the attachment sections 844 of each of
the double-decker lace guide 834, and the double-decker
pass-through lace guide 832 can be secured to a strap (not shown)
which can extend to a position adjacent the heel of a footwear
item, thereby providing additional heal hold-down ability.
[0207] The abrasion preventing guides 846 in the illustrated
multi-zone lacing system generally include three conduits for
supporting the laces 23a, 23b. As shown, each abrasion preventing
guide 846 comprises two crossing diagonal conduits 870 and one
linear conduit 872 to support the first and second laces 23a, 23b
in a substantially frictionless and non-interfering manner. In
alternative embodiments, the functions of the abrasion preventing
guides 846 can be divided among a plurality of separate guides as
desired. In further alternative embodiments, any or all of the
conduits can be replaced by loops of fabric or other material or
straps attached to the footwear or other lace guides. In some
embodiments, the double-decker lace guide 834 and the double-decker
pass-through lace guide 832 can be attached to one another by a
flexible strap with passages through portions of the strap for
receiving the first and second laces. Such a strap can be
configured to distribute a compressive force throughout the ankle
region of the footwear. In some embodiments, such a strap can be
made of neoprene or other durable elastic material.
[0208] Each of the lace guides is generally configured to be
secured to an item of footwear by any suitable means. For example,
the lace guides may be secured to a footwear item by stitches,
adhesives, rivets, threaded or other mechanical fasteners, or the
lace guides can be integrally formed with portions of a footwear
item.
[0209] FIGS. 35-37C, illustrate still another embodiment of a
differential lacing system for tightening a first region of a
footwear item differently than a second region. The system of FIGS.
37A-C is generally a lace doubling system in which a lace can be
passed through a pair of lace guides a second time by pulling the
lace through a slot in a first guide and hooking the lace over a
hook extending from a portion of a second guide. A third lace guide
1008 of any suitable type can also be provided opposite the
tightening mechanism 1000.
[0210] FIG. 37A illustrates a lacing system comprising a lace
tightening device 1000 and a lace 23 extending thorough a plurality
of lace guides including a pair of doubling lace guides 1010. In
some embodiments, doubling lace guides 1010 can be provided in
order to double a number of times a lace 23 passes through a single
lace guide. As shown in FIG. 37C, a lace 23 can be passed through a
given pair of lace guides 1010 twice, thereby providing an
additional tightening force between those two guides. In some
embodiments, each pair of doubling lace guides 1010 comprises a
hook lace guide 1012 and a slotted lace guide 1014.
[0211] FIG. 35 illustrates one embodiment of a lace guide 1014
comprising a curved slot 1020. The slot 1020 is generally sized and
configured to allow a user to grasp a portion of the lace 23 which
extends across the slot 1020. At either side of the slot 1020, the
lace guide 1014 comprises shoulders 1022 configured to
substantially frictionlessly support the lace 23 in the guide 1014.
As with other embodiments of lace guides described herein, the lace
guide 1014 can also comprise a cover 1024 configured to enclose a
conduit 1026 through which the lace 23 passes.
[0212] FIG. 36 illustrates one embodiment of a lace guide 1012
comprising a hook 1030. The hook 1030 generally extends from an
inner portion of the lace guide 1012 and is open so as to allow a
lace to be looped over the hook 1030. In some embodiments, the hook
1030 has a width that is approximately equal to the slot 1020 of
the slotted lace guide 1014. In some embodiments, the hook 1030 can
be molded integrally with the lace guide 1012, while in alternative
embodiments, the hook 1030 can be separately formed and
subsequently attached to the guide 1012. In some embodiments, the
hook 1030 is configured to allow the lace to slide thereon with
minimal friction and minimal abrasion on the laces.
[0213] As with the other lace guides described herein, the slotted
1014 and hooked 1012 lace guides can be made of any suitable
material, and can be attached to a footwear item in any desired
manner. Similarly, many embodiments of lace tightening mechanisms
are described herein which can be used with the doubling lace guide
system of FIGS. 35-37C. A doubling lace guide system can also be
used in connection with any other lacing system described herein or
elsewhere.
[0214] In some embodiments, a plurality of pairs of doubling lace
guides can be provided on a footwear item so as to provide a user
with the option of doubling up laces in a number of sections of the
footwear. In other embodiments, the tightening mechanism 1000 can
include a hook extending from a portion thereof in order to provide
further versatility.
[0215] FIGS. 37A-37C illustrate one embodiment of a sequence for
doubling up a lace with a pair of doubling lace guides 1010. In a
first position, as shown in FIG. 37A, the lace 23 lies across the
curved slot 1020. A user can grasp the lace 23 with a finger or
small tool, such as a key. A loop 1032 of the lace 23 can then be
pulled through the slot towards the hooked lace guide 1012 as shown
in FIG. 37B. The loop 1032 can then be placed over the hook 1030 as
shown in FIG. 37C, so as to double the number of times the lace
passes through the lace guides 1010.
[0216] As discussed above, the lace 23 is preferably a highly
lubricious cable or fiber having a low modulus of elasticity and a
high tensile strength. While any suitable lace may be used, certain
preferred embodiments utilize a lace formed from extended chain,
high modulus polyethylene fibers. One example of a suitable lace
material is sold under the trade name SPECTRA.TM., manufactured by
Honeywell of Morris Township, N.J. The extended chain, high modulus
polyethylene fibers advantageously have a high strength to weight
ratio, are cut resistant, and have very low elasticity. One
preferred lace made of this material is tightly woven. The tight
weave provides added stiffness to the completed lace. The
additional stiffness provided by the weave offers enhanced
pushability, such that the lace is easily threaded through the lace
guides, and into the reel and spool.
[0217] The lace made of high modulus polyethylene fibers is
additionally preferred for its strength to diameter ratio. A small
lace diameter allows for a small reel. In some embodiments, the
lace has a diameter within the range of from about 0.010'' to about
0.050'', or preferably from about 0.020'' to about 0.030'', and in
one embodiment, has a diameter of 0.025''. Of course, other types
of laces, including those formed of textile, polymeric, or metallic
materials, may be suitable for use with the present footwear lacing
system as will be appreciated by those of skill in the art in light
of the disclosure herein.
[0218] Another preferred lace is formed of a high modulus
polyethylene fiber, nylon or other synthetic material and has a
rectangular cross-section. This cross-sectional shape can be formed
by weaving the lace material as a flat ribbon, a tube, or other
suitable configuration. In any case the lace will substantially
flatten and present a larger surface area than a cable or other
similar lace and will thereby reduce wear and abrasion against the
lace guides and other footwear hardware. In addition, there is a
sufficient amount of cross-sectional material to provide an
adequate tension strength, while still allowing the lace to
maintain a sufficiently thin profile to be efficiently wound around
a spool. The thin profile of the lace advantageously allows the
spool to remain small while still providing the capacity to receive
a sufficient length of lace. Of course, the laces disclosed herein
are only exemplary of any of a wide number of different types and
configurations of laces that are suitable to be used with the
lacing system described herein.
[0219] With reference to FIGS. 38A through 51, additional
embodiments of a lacing system 22 are shown. FIGS. 38A and 38B are
side views of an alternative tightening mechanism 1200. The
tightening mechanism 1200 includes a base member 1202 including an
outer housing 1203 and a mounting flange 1204 disposed near the
bottom of outer housing 1203. In alternative embodiments, the
flange 1204 is disposed a distance from the bottom of outer housing
1203. Mounting flange 1204 may be mounted to the outside structure
of an article of footwear, or may be mounted underneath some or all
of the outer structure of the footwear, to which the tightening
mechanism 1200 is attached. Base member 1202 is preferably molded
out of any suitable material, as discussed above, but in one
embodiment, is formed of nylon. As in other embodiments, any
suitable manufacturing process that produces mating parts fitting
within the design tolerances is suitable for the manufacture of
base 1202 and the other components disclosed herein. Tightening
mechanism 1200 further includes a control mechanism, such as a
rotatable knob assembly 1300, mechanically coupled thereto.
Rotatable knob assembly 1300 is slideably movable along an axis A
between two positions with respect to the outer housing 1203.
[0220] In a first, also referred to herein as a coupled or an
engaged position (shown in FIG. 38A), knob 1300 is mechanically
engaged with an internal gear mechanism located within outer
housing 1203, as described more fully below. In a second, also
referred to herein as an uncoupled or a disengaged position (shown
in FIG. 38B), knob 1300 is disposed upwardly with respect to the
first position and is mechanically disengaged from the gear
mechanism. Disengagement of knob 1300 from the internal gear
mechanism is preferably accomplished by pulling the control
mechanism outward, away from mounting flange 1204, along axis A.
Alternatively, the components may be disengaged using a button or
release, or a combination of a button and rotation of knob 1300, or
variations thereof, as will be appreciated by those of skill in the
art and as herein described above.
[0221] FIG. 39 illustrates a top perspective exploded view of one
embodiment of a tightening mechanism 1200. The embodiment of FIG.
39 illustrates a base unit 1202, a spool 1240, and a knob assembly
1300. Spool 1240 is generally configured to be placed within a
housing 1203. Knob assembly 1300 can then be assembled with housing
1203 and spool 1240 to provide tightening mechanism 1200.
Tightening mechanism 1200 may also be referred to herein as a
lacing device, a lace lock, or more simply as a lock.
[0222] FIGS. 40A through 40C illustrate one embodiment of base
member 1202. Base 1202 includes an outer housing 1203 and a
mounting flange 1204. Preferably, flange 1204 extends
circumferentially around housing 1203. In alternative embodiments,
flange 1204 extends only partially around the circumference of
housing 1203 and may comprise one or more distinct portions. Though
flange 1204 is shown with a circular or ovular shape, it may also
be rectangular, square, or any of a number of other regular or
irregular shapes. Flange 1204 preferably includes a trough 1208
extending substantially the length of the outer circumference of
flange 1204. The central portion of trough 1208 is preferably
thinner than the rest of flange 1204, thereby facilitating
attachment of base 1202 to the footwear by stitching. Though
stitching is preferred, as discussed above, base 1202 may be
securely attached by any suitable method, such as for example, by
adhesives, rivets, threaded fasteners, and the like, or any
combinations thereof For example, adhesive may be applied to a
lower surface 1232 of base member 1202. Alternatively, mounting
flange 1204 may be removeably attached to the footwear, such as by
a releasable mechanical bonding structure in the form of
cooperating hook and loop structures. Flange 1204 is preferably
contoured to curve with the portion of the footwear to which it is
attached. One such contour is illustrated in FIGS. 38A and 38B and
in FIGS. 45A and 45B. In some embodiments, the contour is flat.
Flange 1204 is also preferably resilient enough to at least
partially flex in response to forces which cause the structure of
the footwear to which it is mounted to flex.
[0223] Outer housing 1203 of base member 1202 is generally a hollow
cylinder having a substantially vertical wall 1210. Housing wall
1210 may include a minimal taper outward toward flange 1204 from
the upper most surface 1332 of housing 1203 the base of housing
1203. Housing 1203 preferably includes sloped teeth 1224 formed
onto its upper most surface 1332 such as those found on a ratchet,
as has been described herein above. These base member teeth 1224
may be formed during the molding process, or may be cut into the
housing after the molding process, and each defines a sloped
portion 1226 and a substantially vertical portion 1228. In one
embodiment, vertical portion 1228 may include a back cut vertical
portion 1228 in which it is less than vertical, as described
below.
[0224] In one embodiment, the sloped portion 1226 of each tooth
1224 allows relative clockwise rotation of a cooperating control
member, e.g. knob assembly 1300, while inhibiting relative
counterclockwise rotation of the control member. Of course, the
teeth direction could be reversed as desired. The number and
spacing of teeth 1224 controls the fineness of adjustment possible,
and the specific number and spacing can be designed to suit the
intended purpose by one of skill in the art in light of this
disclosure. However, in many applications, it is desirable to have
a fine adjustment of the lace tension, and the inventors have found
that approximately 20 to 40 teeth are sufficient to provide an
adequately fine adjustment of the lace tension.
[0225] Base member 1202 additionally contains a pair of lace entry
holes 1214 for allowing each end of a lace to enter therein and
pass through internal lace openings 1230. Lace entry holes 1214 and
internal lace openings 1230 preferably define elongated lace
pathways that correspond to the annular groove of spool 1240.
Preferably, lace entry holes 1214 are disposed on vertical wall
1210 of housing 1203 directly opposed from each other. As discussed
above, base member 1202 lace entry holes 1214 may be made more
robust by the addition of higher durometer materials either as
inserts or coatings to reduce the wear caused by the laces abrading
against the base member 1202 entry holes 1214. Additionally, the
site of the entry hole can be rounded or chamfered to provide a
larger area of contact with the lace to further reduce the pressure
abrasion effects of the lace rubbing on the base unit. In the
illustrated embodiment, base member 1202 includes lace opening
extensions 1212 including rounded entry hole edges 1216 to provide
additional strength to the housing 1203 in the area of the lace
entry holes 1214. FIG. 41 shows a modified entry hole edge 1216. As
discussed above, a lace guide may be formed integrally with the
base member 1202 and can be configured depending upon the specific
application of the lacing system 22. An embodiment with an
integrated lace guide is shown attached to footwear in FIG.
47B.
[0226] It is preferable that the inner bottom surface 1220 of the
base member 1202 is highly lubricious to allow mating components an
efficient sliding engagement therewith. Accordingly, in one
embodiment, a washer or bushing (not shown) is disposed within the
cylindrical housing portion 1203 of the base member 1202, and may
be formed of any suitable lubricious polymer, such as PTFE, for
example, or may be formed of a lubricious metal. Alternatively, the
inner bottom surface 1220 of the base member 1202 may be coated
with any of a number of coatings (not shown) designed to reduce its
coefficient of friction and thereby allow any components sharing
surface contact therewith to easily slide. One advantage of the
illustrated embodiment is the reduction in separate movable
components required to manufacture tightening mechanism 1200. Fewer
parts reduces the cost of manufacture and preferably results in
lighter weight mechanisms. Overall, tightening mechanism 1200 is
small and compact with few moving parts. Light weight and fewer
moving parts also reduce the frictional forces generated on the
components within lacing device 1200 during use.
[0227] An inner surface 1218 of housing 1203 is preferably
substantially smooth to facilitate winding of the lace about the
spool residing within housing 1203 during operation. When spool
1240 is inserted into housing 1203, inner surface 1218 cooperates
with annular groove 1256 to hold the wound lace. Preferably, the
material selected for inner surface 1218 is adapted to reduce the
friction imparted upon the lace if the lace rubs against the
surface when the lace is wound into or released from housing 1203.
FIG. 40B shows a top view of base member 1202. Base 1202 preferably
includes a central axial opening 1222. In a preferred embodiment,
opening 1222 is adapted to receive a threaded insert 1223. Insert
1223 is preferably metallic or some other material offering
suitable strength to securely retain axial pin 1360 (e.g., FIG.
39).
[0228] FIG. 40C illustrates grooves 1286 which are preferably
included in base member 1202. Grooves 1286 further reduce the
material utilized in the illustrated embodiment, thereby reducing
the weight of the completed tightening mechanism 1200 and providing
for improved molding by providing substantially similar wall
thicknesses throughout base member 1202. Also shown is part indicia
1236. Indicia 1236 may be used to indicate the "handedness" of a
particular part. In some applications, namely on a pair of footwear
having a united adapted for use with a right foot and another unit
adapted for use with a left foot, it may be desirable to have
lacing devices 1200 attached to the shoes operate in different
directions. Indicia 1236 help coordinate the proper components for
each lacing device 1200. Indicia 1236 may be used on some or all of
the components described herein. Indicia 1236 may be formed during
the molding process or may be painted onto the component parts.
[0229] With additional reference to FIG. 39, as well as to FIGS.
42A through 42E, a spool 1240 is provided and configured to reside
within housing 1203 of base member 1202. Spool 1240 is preferably
molded out of any suitable material, as discussed above, but in one
preferred embodiment, is formed of nylon and may include a metal
insert, preferably along the central axis. In alternative
embodiments, spool 1240 is cast or molded from any suitable polymer
or formed of metal such as aluminum. Spool 1240 preferably includes
an upper flange 1253, a lower flange 1242, and a substantially
cylindrical wall 1252 therebetween. A central axial opening 1286
extends through spool 1240 and includes inner side walls 1288. A
bottom surface 1254 of upper flange 1253 cooperates with the outer
surface of cylindrical wall 1252 and an upper surface 1244 of lower
flange 1242 to form annular groove 1256. Annular groove 1256 is
advantageously adapted to receive the spooled lace as it is wound
around spool 1240.
[0230] In one preferred embodiment, bottom surface 1254 of upper
flange 1253 and upper surface 1244 of lower flange 1242 are both
angled relative to the horizontal axis of spool 1240. As shown in
FIG. 42B, the distance between the surfaces adjacent cylindrical
wall 1252 is smaller than the distance between the surfaces when
measured from the outer diameter of the flanges. As lace 23 is
wound around spool 1240, the effective diameter of the combined
lace and spool increases. Advantageously, as tension is placed on
lace 23, the coiled lace 23 will fan out, minimizing the effective
diameter of the spool plus wound lace. The smaller the effective
diameter, the greater the torque placed on lace 23 when knob 1300
is rotated. In alternative embodiments, spool 1240 includes one or
more additional flanges to define additional annular grooves.
[0231] Preferably, the periphery of an upper surface 1260 of upper
flange 1253 is configured to include sloped teeth 1262. Sloped
teeth 1262 may be formed during the molding process, if spool 1240
is molded, or may be subsequently cut therein, and each defines a
sloped portion 1264 and a substantially vertical portion 1266 as
measured from upper surface 1260. Vertical portion 1266 is
preferably back cut such that it is slightly less than vertical,
preferably in the range of zero (0) and twenty (20) degrees less
than ninety (90) degrees. More preferably, it is angled between one
(1) and five (5) degrees less than vertical. Most preferably, it is
angled about three (3) degrees less than vertical. In one
embodiment, vertical portion 1266 of each tooth 1262 cooperates
with teeth formed on a control member, e.g. knob teeth 1308,
causing relative counter-clockwise rotation of spool 1240 upon
counter-clockwise rotation of the cooperating control member,
thereby winding the lace about the cylindrical wall 1252 of spool
1240. Of course, the teeth direction could be reversed as desired.
The slight angle less than vertical, or back cut, is preferable as
it increases the strength of the mating relationship between spool
teeth 1262 and the control member. As lace tension increases, spool
1240 and knob 1300 may tend to disengage. Back cutting the vertical
portion of the teeth helps prevent unintended disengagement.
[0232] Advantageously, spool 1240 is dimensioned to reduce the
overall size of tightening mechanism 1200. Adjustments may be made
with the ratio of the diameter of cylindrical wall 1252 of spool
1240 and the diameter of control knob 1300 to affect the torque
that may be generated within tightening mechanism 1200 during
winding. As lace 23 is wound about spool 1240, its effective
diameter will increase and the torque generated by rotating knob
1300 will decrease. Preferably, torque will be maximized while
maintaining the compact size of the lace lock 1200. For purposes of
non-circular cross-sections, the diameter as used herein refers to
the diameter of the best fit circle which encloses the
cross-section in a plane transverse to the axis of rotation.
[0233] In many embodiments of the present invention, the knob 1300
will have an outside diameter of at least about 0.5 inches, often
at least about 0.75 inches, and, in one embodiment, at least about
1.0 inches. The outside diameter of the knob 1300 will generally be
less than about 2 inches, and preferably less than about 1.5
inches.
[0234] The cylindrical wall 1252 defines the base of the spool, and
has a diameter of generally less than about 0.75 inches, often no
more than about 0.5 inches, and, in one embodiment, the diameter of
the cylindrical wall 1252 is approximately 0.25 inches.
[0235] The depth of the annular groove 1256 is generally less than
a 1/2 inch, often less than 3/8 of an inch, and, in certain
embodiments, is no more than about a 1/4 inch. In one embodiment,
the depth is approximately 3/16 of an inch. The width of the
annular groove 1256 at about the opening thereof is generally no
greater than about 0.25 inches, and, in one embodiment, is no more
than about 0.13 inches.
[0236] The knob 1300 generally has a diameter of at least about
300%, and preferably at least about 400% of the diameter of the
cylindrical wall 1252.
[0237] The lace for cooperating with the forgoing cylindrical wall
1252 is generally small enough in diameter that the annular groove
1256 can hold at least about 14 inches, preferably at least about
18 inches, in certain embodiments at least about 22 inches, and, in
one embodiment, approximately 24 inches or more of length,
excluding attachment ends of the lace. At the fully wound end of
the winding cycle, the outside diameter of the cylindrical stack of
wound lace is less than 100% of the diameter of the knob 1300, and,
preferably, is less than about 75% of the diameter of the knob
1300. In one embodiment, the outer diameter of the fully wound up
lace is less than about 65% of the diameter of the knob 1300.
[0238] By maintaining the maximum effective spool diameter less
than about 75% of the diameter of the knob 1300 even when the spool
is at its fully wound maximum, maintains sufficient leverage so
that gearing or other leverage enhancing structures are not
necessary. As used herein, the term effective spool diameter refers
to the outside diameter of the windings of lace around the
cylindrical wall 1252, which, as will be understood by those of
skill in the art, increases as additional lace is wound around the
cylindrical wall 1252.
[0239] In one embodiment, approximately 24 inches of lace will be
received by 15 revolutions about the cylindrical wall 1252.
Generally, at least about 10 revolutions, often at least about 12
revolutions, and, preferably, at least about 15 revolutions of the
lace around the cylindrical wall 1252 will still result in an
effective spool diameter of no greater than about 65% or about 75%
of the diameter of the knob 1301.
[0240] In general, laces having an outside diameter of less than
about 0.060 inches, and often less than about 0.045 inches will be
used. In certain preferred embodiments, lace diameters of less than
about 0.035 will be used.
[0241] Side edge 1258 of upper flange 1253 and side edge 1248 of
lower flange 1242 are adapted to slidingly engage the inner wall
surface 1218 of the housing 1203 of the base member 1202. Sliding
engagement with the inner wall surface 1218 helps stabilize spool
1240 inside housing 1203. Similarly, inner side walls 1288 of axial
opening 1286 of spool 1240 slidingly engage the axial body 1370 of
axial pin 1360 to stabilize spool 1240 during use of lacing device
1200. Lower surface 1246 of lower flange 1242 may be configured for
efficient sliding engagement with inner bottom surface 1220 of base
member 1202. In FIG. 42C, lower surface 1246 is shown substantially
flat. In alternative embodiments, lower surface 1246 may be
provided with a lip (not shown) that offers a small surface area
that contacts bottom surface 1220 of base member 1202.
[0242] As illustrated in FIGS. 42A through 42B, lower flange 1242
of spool 1240 preferably includes lace gaps 1250. Lace gaps 1250
facilitate attachment of the lace to the spool as described below.
Lace gaps 1250 also facilitate insertion of spool 1240 within
housing 1203 after lace 23 has been attached to spool 1240.
Preferably, the edges of lace gaps 1250 are rounded. Rounded edges
reduce the potential for the lace to catch on the gaps which could
potentially adversely kink the lace. Advantageously, the edges of
all the components that directly contact the lace are preferably
rounded. This is especially advantageous where the lace slides
against these edges.
[0243] As described in detail above, spool 1240 may include one or
more annular grooves 1256 that are configured to receive lace 23.
Preferably, the ends of lace 23 are connected to spool 1240, either
fixedly or removeably, in any one of a number of suitable
attachment methods, including using set screws, crimps, or
adhesives. In a preferred embodiment shown in FIG. 42E, lace 23 is
removeably secured to spool 1240. Upper flange 1253 of spool 1240
preferably includes two sets of three retaining holes (see FIG.
42A) adapted to receive lace 23. An inner side wall 1268 of upper
flange 1253 cooperates with side walls 1274 of a central divider
1272 to define knot cavities 1278. In a preferred embodiment, side
walls 1268 and 1274 include one or more lace indents 1276 to
facilitate insertion of lace 23 into the retaining holes. In
alternative embodiments, lace indents 1276 are not included.
[0244] Lace 23 is preferably secured to spool 1240 by threading
lace 23 through one of the lace holes 1214 in base member 1202.
Lace 23 exits internal lace opening 1230 of housing 1203 and is
directed toward spool 1240. Lace 23 is then passed through lace gap
1250 and upwards through entrance hole 1280 in upper flange 1253.
Next, lace 23 is passed downward through loop hole 1282a and back
upwards through loop hole 1282b. A portion of lace 23 therefore
forms a loop disposed above upper flange 1253 and between entrance
hole 1280 and loop hole 1282a. The end of lace 23 is passed through
the loop and tension is placed on the portion of lace 23 extending
downwards from entrance hole 1280 to tighten the resulting knot
1292. Preferably, knot 1292 is positioned such that it rests within
knot cavity 1278 by passing the end of lace 23 through the loop
from outside inwards, as shown in FIG. 42E. A second knot 1292 is
similarly formed. Advantageously, wall 1252 of spool 1240 may also
include lace groove 1284. Lace groove 1284 captures the portion of
lace 23 that extends into annular groove 1256 after lace 23 is tied
to spool 1240. By accommodating this portion of lace 23 within wall
1252, the winding of lace 23 around spool 1240 is cleaner and less
compression and pressure is placed upon the portion of lace 23
extending into annular groove 1256. Lace groove 1284 further
minimizes the diameter of spool 1240 to maximize the torque that
may be placed on lace 23 as discussed above. In alternative
embodiments, lace groove 1284 is not included.
[0245] Although the above method of securing lace 23 to spool 1240
is preferred, other means for attaching the lace are also
envisioned by the inventors. The method for attaching lace 23 to
spool 1240 as described above is advantageous as it allows for a
simple, secure connection to spool 1240 without requiring
additional connection components. This saves weight and decreases
the assembly time required to manufacture footwear incorporating a
tightening mechanism 1200 as described herein. Further, this type
of connection allows for simplified and easy replacement of lace 23
when it has become worn.
[0246] Referring now to FIGS. 39, 43A, and 43B, tightening
mechanism 1200 is further provided with a control knob assembly
1300 which is configured to be incrementally rotated in a forward
rotational direction, i.e., in a rotational direction that causes
lace 23 to wind around spool 1240. Toward this end, control knob
1300 preferably includes a series of integrally-mounted pawls 1302
that engage the corresponding series of teeth 1224 on outer housing
1203 of base 1202. Pawls 1302 are preferably engaged with base
teeth 1224 only when the control knob 1300 is in the coupled or
engaged position, as shown in FIG. 38A. The tooth/pawl engagement
inhibits knob 1300, and mechanically connected spool 1240, from
being rotated in a backwards direction (i.e., in a rotational
direction opposite the rotational direction that winds lace 23
around spool 1240) when knob 1300 is in the engaged position. This
configuration prevents the user from inadvertently winding control
knob 1300 backwards, which could cause lace 23 to kink or tangle in
spool 1240. In alternative embodiments, pawls 1302 may be
configured, for instance by modifying the sloped surface 1304 of
pawls 1302, to allow incremental rotation of knob 1300 in the
reverse direction. Such an embodiment is advantageous as it could
allow for incremental decrease of the tension placed on the
lace.
[0247] Knob assembly 1300 preferably includes a knob 1301, a spring
member 1340, and a cap member 1350. As shown in FIG. 43A, the under
side of knob 1301 further includes teeth 1308 for engagement with
spool teeth 1262 of spool 1240. Knob teeth 1308 include sloping
portions 1310 and vertical portions 1312. One or more cap
engagement openings 1314 extend through knob 1301 to facilitate
attachment of cap 1350 to knob 1301. Preferably, cap 1350 includes
one or more downwardly extending engagement arms 1352 of (FIG. 39)
which may cooperate with one or more engagement openings 1324. In a
preferred embodiment, arms 1352 are heat staked in place. As will
be appreciated by those of skill in the art, cap 1350 may be
permanently or removably coupled to knob 1301 in any one of a
number of ways. For example, in alternative embodiments, engagement
arms 1352 may include prongs or protrusions at the ends thereof for
removably securing cap 1350 to knob 1301. As shown in FIG. 39, an
upper surface 1354 of cap 1350 may advantageously include
advertising indicia 1356, which may be in the form of raised
letters or symbols or, alternatively, be visually differentiated
from the rest of upper surface 1354 with colors. As such,
tightening mechanism may be used as an advertising tool. In other
embodiments, upper surface 1354 does not include indicia 1356.
[0248] An outer engagement surface 1319 of knob 1301 is preferably
formed with knurls 1318 or some other friction enhancing feature.
In preferred embodiments, the outer engagement surface 1317 is made
of a softer material that the rest of knob 1301 to increase the
tactile feel of knob 1301 and to ease the manipulation of the
lacing device 1200 to apply tension to lace 23.
[0249] As shown in FIGS. 39 and 43B, an upper side of knob 1301 is
configured to retain spring member 1340. Preferably, spring member
1340 is of a unitary construction and includes engagement arms
1342. In a preferred embodiment, engagement tabs 1322 of knob 1301
cooperate with outer side walls 1326 of central engagement
projection 1324 to retain spring 1340. As shown in FIGS. 45A and
45B, engagement arms 1342 are preferably retained within knob 1300,
but are secured such that they can move outwards in cavity 1334
when tightening mechanism 1200 is engaged or disengaged. FIG. 46
shows a top perspective cross sectional view of tightening
mechanism 1200 in the disengaged position.
[0250] In a preferred embodiment, axial pin 1360 secures knob
assembly 1300, spool 1240, and base member 1202. Axial pin 1360 is
preferably made of a metallic or other material of sufficient
strength to withstand the forces imparted on tightening mechanism
1200. Axial pin 1360 also preferably includes a multitude of
regions with varying diameters, including a cap 1364 having an
upper surface 1363, an upper side engagement surface 1364, a lower
side engagement surface 1366, and a lower surface 1367. Upper side
engagement surface 1364 preferably tapers outward from upper
surface 1363 toward lower side engagement surface 1366. Lower side
engagement surface 1366 preferably tapers inward from upper side
engagement surface 1364 toward lower surface 1367. Preferably, the
diameter of axial pin 1360 is largest along the circumference of
the intersection of upper and lower side engagement surfaces 1364
and 1366. The diameter of upper surface 1363 is preferably greater
than the diameter of lower surface 1367.
[0251] Upper surface 1363 of cap 1350 also preferably includes one
or more engagement holes 1374 for rotating pin 1360 into threaded
engagement with base member 1202. In other embodiments, a singe,
centrally located engagement hole is used with a non-circular
opening as will be understood by those of skill in the art. Upper
surface 1363 may also include indicia 1376. In alternative
embodiments, indicia 1376 is not included.
[0252] Disposed adjacent and just below cap 1362 is upper sleeve
1368. The diameter of upper sleeve 1368 is preferably smaller than
the diameter of lower surface 1367. Pin body 1370 is preferably
disposed adjacent and just below upper sleeve 1368. The diameter of
pin body 1370 is preferably smaller than the diameter of upper
sleeve 1360. Finally, threaded extension 1372 preferably extends
downward from the lower surface of pin body 1370. Though extension
1372 is preferably threaded, other mating or engagement means may
be used to couple pin 1360 to base 1202.
[0253] Axial pin 1360 includes multiple diameters to correspond to
the varying internal diameters of the axial openings in knob 1300,
spool 1240, and base member 1202, respectively. Corresponding
diameters of these components helps stabilize the tightening
mechanism 1200. Pin body 1370 is adapted to slidingly engage with
inner side wall 1288 of seal opening 1286 of spool 1240. Upper
sleeve 1368 is adapted to slidingly engage with inner wall 1330 of
axial opening 1316 of knob 1301. Threaded extension 1372 couples
with insert 1223 of base member 1202 to secure axial pin 1360 to
base member 1202. As will be appreciated by those of skill in the
art, axial pin 1360 may be permanently or removably attached to
base member 1202. For example, an adhesive may be used, either
alone or in combination with threads.
[0254] FIGS. 44A and 44B are top views tightening mechanism 1200 in
engaged and disengaged positions, respectively. Referring now to
FIGS. 45A and 45B, knob 1300 is illustrated to show its moveability
between the two positions, coupled or engaged (FIG. 45A) and
uncoupled or disengaged (FIG. 45B). In the uncoupled position, lace
23 may be manually removed from spool 1240, by, for example,
putting tension on lace 23 in a direction away from tightening
mechanism 1200.
[0255] Advantageously, the diameter of upper sleeve 1368 of axial
pin 1360 is larger than the inner diameter of axial opening 1286 of
spool 1240. As such, upper sleeve 1368 of axial pin 1360 serves as
an upper restraint for movement of spool 1240 along axis A, as can
be seen in FIG. 45A. Movement along axis A is limited such that
when knob 1300 is in the disengaged position, as shown in FIG. 45B,
knob teeth 1308 disengage from spool teeth 1262, allowing free
rotation of spool 1240 in the disengaged position. In this
disengaged state, lace 23 is manually removed from spool 1240. In
preferred embodiments, only a single control, e.g. knob 1300, is
needed to actuate the tightening mechanism 1200. Push it in to
tighten the lacing system 22 and pull it out to loosen the lacing
system 22.
[0256] In a preferred embodiment, spring engagement arms 1342
engage upper side engagement surfaces 1364 of cap 1362 in the
uncoupled position and engage lower side engagement surface 1366 in
the coupled position. In the coupled position, arms 1342 engage
lower side engagement surface 1366 to bias knob 1300 in the coupled
position. In the uncoupled position, arms 1342 engage upper side
engagement surface 1364 to bias knob 1300 in the uncoupled
position. Although spring 1340 biases knob 1300 in the coupled and
the uncoupled positions in this embodiment, other options are
available as will be understood by one of skill in the art. For
example, knob 1300 could be biased only in the engaged position,
such that it can be pulled out to disengage spool 1240, however, as
soon as it is released it slides back into the engaged
position.
[0257] In a preferred embodiment, knob 1300 will be biased in each
of the coupled and the uncoupled positions such that the user is
required to either push the knob in or pull the knob out against
the bias to engage or disengage, respectively, the tightening
mechanism 1200. Advantageously, engaging and disengaging tightening
mechanism 1200 is accompanied by a "click" or other sound to
indicate that it has changed positions. Tightening mechanism 1200
may also include visual indicia that the mechanism is disengaged,
such as a colored block that is exposed from under the knob when in
the disengaged position. Audible and visual indications that the
mechanism is engaged or disengaged contribute to the user
friendliness of the lacing systems described herein.
[0258] Tightening mechanism 1200 may be removably or securely
mounted to a variety of locations on footwear, including the front,
back, top, or sides. Base member 1202 illustrated in FIGS. 38A
through 41 is preferably adapted to be attached to the side portion
of a boot or shoe. FIGS. 47A through 47C show tightening mechanism
1200 securely stitched to the upper of a shoe near the eyestay of
the shoe. Lace guides may be incorporated onto the base 1202 of the
mechanism 1200, as shown in FIG. 47B, or they may be separate. In
some embodiments, substantially all of tightening mechanism 1200 is
secured within the footwear structure, leaving only knob 1300 and a
small portion of housing 1203 exposed. In some such embodiments,
lace holes 1214 are positions substantially along the axis of the
eyestay to which the mechanism 1200 is attached (see FIG. 47B).
When mechanism 1200 is attached in such a manner, it is preferable
that flange 1204 extend in the direction opposite lace holes 1214,
allowing mechanism 1200 to be positioned at or near the edge of the
upper adjacent the tongue. Mechanism 1200 may also be positioned in
other areas of the footwear including near the sole or toe
portions. Lacing system 22 also includes tongue guides 1380 and
lace guides 1392, as will be discussed in greater detail below.
[0259] FIGS. 48B and 49B show an alternate preferred embodiment of
tightening mechanism 1200 including a modified base member 1202.
Base member 1202 is configured with a lower outer housing 1208 and
an upper outer housing 1203. Lower outer housing 1208 slops outward
from upper outer housing 1203 toward flange 1204. The upper most
portion of lower outer housing 1208 preferably includes a
protective lip 1290. In a preferred embodiment, protective lip 1290
extends partway up the outer engagement surface 1319 of knob
assembly 1300 and only partway around the circumference of knob
1300. In alternative embodiments, the lip extends fully around the
circumference of the knob. In still other embodiments, the lip
extends only partway around the circumference of the knob, but
extends upwards over substantially the entire width of the outer
engagement surface 1319 of knob 1300.
[0260] In the embodiment illustrated in FIGS. 48A and 48B, lower
outer housing 1208 preferably includes lace pathways 1238 leading
from rear surface 1232 of base member 1202 and ending at lace holes
1214. As shown in FIG. 48A, lace holes 1214 preferably extend
through the upper surface 1332 of upper outer housing 1203. Flange
1204 and lower outer housing 1208 are shaped in a substantially
curved manner to accommodate attachment surfaces with large
inherent curvature, such as, for example on the rear portion of a
boot or shoe.
[0261] Base member 1202 illustrated in FIGS. 48A through 49B is
preferably adapted to be attached to the rear portion of a boot or
shoe. FIGS. 50A and 50B show tightening mechanism 1200 securely
stitched to the rear portion of a shoe. Advantageously, after
passing through the upper most tongue guide 1380, lace 23 enters
lace guide 1392 and is directed around the ankle portion of the
shoe toward tightening mechanism 1200. Lace guide 1392 is
preferably made of a low sliding resistance polymer, such as Teflon
or nylon, and preferably includes rounded edges. The upper most
lace guides 1392 preferably have only one entrance point on each
side of the shoe, the exit point being directly coupled to the lace
pathway 1338 of rear mounted tightening mechanism 1200.
[0262] Lacing system 22 preferably includes tongue guides 1380,
shown in greater detail in FIG. 51. Tongue guide 1308 preferably
includes mounting flange 1382, sliding surfaces 1384a and 1384b and
central cap 1388. Central cap 1388 is preferably disposed in a
raised manner above sliding surface 1384 by one or more support
legs 1390. Sliding surfaces 1384a and 1384b are preferably disposed
in different planes such that a generally vertical ledge 1386 is
formed therebetween. The different planes of sliding surface 1384
helps reduce friction by limiting lace 23 from sliding against
itself Mounting flange 1382 may be sewn under one or more of the
outer layers of shoe tongue or to the outer surface of the tongue.
In alternative embodiments, tongue guide 1380 is attached to the
tongue bye adhesive, rivets, etc., or combinations thereof, as will
be understood by those of skill in the art. Support legs 1390 are
preferably angled to accommodate the different ingress and egress
directions of lace 23 as it enters the central cap portion
1388.
[0263] As with the other components of lacing systems described
herein, the tightening mechanism 1200, the tongue guides, and the
other lace guides described above in connection with tightening
mechanism 1200 can be made of any suitable material, and can be
attached to footwear in any suitable manner. The various component
parts of the lacing system may be used in part or in whole with
other components or systems described herein. As discussed above,
lace 23 may be formed from any of a wide variety of polymeric or
metal materials or combinations thereof, which exhibit sufficient
axial strength and suppleness for the present application. In one
preferred embodiments, lace 23 comprises a stranded cable, such as
a 7 strand by 7 strand cable manufactured of stainless steel. In
order to reduce friction between lace 23 and the guide members
through which lace 23 slides, the outer surface of the lace 23 is
preferably coated with a lubricous material, such as nylon or
Teflon. The coating also binds the threads of the stranded cable to
ease insertion of the lace into the lace guides of the system and
attachment of the lace to the gear mechanism within lacing device
1200. In a preferred embodiment, the diameter of lace 23 is in the
range of from about 0.024 inches to about 0.060 inches inclusive of
the coating of lubricous material. More preferably, the diameter of
lace 23 is in the range of from about 0.028 to about 0.035. In one
embodiment, lace 23 is preferably approximately 0.032 inches in
diameter. A lace 23 of at least five feet in length is suitable for
most footwear sizes, although smaller or larger lengths could be
used depending upon the lacing system design. For example, lacing
systems for use with running shoes may preferably use lace 23 in
the range from about 15 inches to about 30 inches.
[0264] With reference to FIGS. 52A through 59B, additional
embodiments of a lacing system 22 are shown. FIGS. 52A and 52B are
top and perspective views, respectively, of an alternative
tightening mechanism 1400. Tightening mechanism 1400 may also be
referred to herein as a lacing device, a lace lock, or more simply
as a lock. As with other embodiments presented herein, tightening
mechanism 1400 may be may be configured for placement in any of a
variety of positions on the footwear including in the ankle region
(for example on snow board boots or hiking boots with ankle
support), on the tongue (if the footwear includes a tongue), on the
instep area of the footwear, or on the rear of the footwear. It is
preferably molded out of any suitable material, as discussed above,
but in one embodiment, comprises nylon, metal, and rubber. As in
other embodiments, any suitable manufacturing process that produces
mating parts fitting within the design tolerances is suitable for
the manufacture of tightening mechanism 1400 and its
components.
[0265] FIG. 53 illustrates a top perspective exploded view of one
embodiment of a tightening mechanism 1400. The embodiment of FIG.
53 includes a base member (or bayonet) 1402, a housing assembly
1450 including a spool assembly 1480, and a control mechanism, such
as a rotatable knob assembly 1550. Housing assembly 1450 is
configured to mount within inner cavity 1406 of bayonet 1402 while
spool assembly 1480 is generally configured to be placed within an
inner cavity 1462 of housing 1460. Knob assembly 1550 can be
mechanically coupled to housing 1460 to provide tightening
mechanism 1400. In some embodiments, tightening mechanism 1400
further includes a coiler assembly 1600. Rotatable knob assembly
1550 is preferably slideably movable along an axis A between two
positions with respect to housing 1560.
[0266] In many embodiments, the spool assembly 1480 is off axis
from the knob assembly 1550. This allows for a mechanically geared
tightening mechanism 1400 which maintains a low profile relative to
the surrounding mounting surface.
[0267] Bayonet 1402 may include a mounting flange 1404 useful for
mounting tightening mechanism 1400 to the outside structure of an
article of footwear. Preferably, flange 1404 extends
circumferentially around inner and outer sections 1412 and 1414. In
alternative embodiments, flange 1404 extends only partially around
the circumference of sections 1412 and 1414 and may comprise one or
more distinct portions. Though flange 1404 is shown with an ovular
shape, it may also be rectangular, circular, square, or any of a
number of other regular or irregular shapes. Flange 1404 may be
similar to flange 1204 disclosed herein above.
[0268] Mechanism 1400 may be mounted on the outer surface of the
footwear or underneath some or all of the outer structure of the
footwear by means of stitching, hook and loop fasteners, rivets, or
the like. Though tightening mechanism 1400 need not be manufactured
in various components, it may be advantageous to do so. For
example, portions of tightening mechanism 1400 may be manufactured
at various locations and later brought together to form the
completed mechanism. In one instance, bayonet 1402 may be fixed to
the footwear independent from the rest of tightening mechanism
1400. The footwear with bayonet 1402 may then be transported to one
or more locations where the rest of tightening mechanism 1400 is
installed. In addition, modularity allows a user of an article
incorporating mechanism 1400 to replace individual components when
needed.
[0269] As with other embodiments disclosed herein, tightening
mechanism 1400 may be mounted in a number of different positions on
the footwear, including, but not limited to, on the tongue, on the
ankle portion in the case of a high top such as a hiking boot or a
snow board boot, on the instep of the footwear, or on the rear of
the footwear. If the footwear includes an inner boot, tightening
mechanism may be mounted thereon rather than on the surface of the
footwear. If the footwear includes a canopy or other covering
across the instep area, the mechanism 1400 may be mounted thereon
or adjacent thereto. Embodiments of tightening mechanism 1400 may
be used with some or all of the various lacing components disclosed
herein above. For example, tightening mechanism could be used with
the multi-zone lacing system 800 shown in FIG. 28. Embodiments of
mechanism 1400 could be used in place of either first 802 or second
804 lace tightening mechanisms which are shown arranged to tighten
first 23a and second 23b laces.
[0270] Referring now to FIGS. 54A through 54F, there are shown a
number of different views of the bayonet 1402. Side views, such as
54E and 54I, are representative of both sides of the illustrated
embodiment. Generally, tightening mechanism 1400 is symmetrical
along its central axis (except for indicia located in various
places on the mechanism). This embodiment of bayonet 1402 is
configured for use at a location remote from the tongue, or midline
of the lacing system, for instance on the side of the footwear or
on the rear of the footwear. Inner section 1412, disposed on the
side facing the footwear, preferably extends further from flange
1404 than does section 1412 to accommodate lace exit holes 1410.
FIG. 54A is a rear view of bayonet 1402. FIG. 54B is a perspective
rear view of bayonet 1402 showing lace entry holes 1410. FIG. 54C
is a top view of bayonet 1402 showing lace exit holes 1408. Lace 23
may enter through lace entry holes 1410 and exit lace exit holes
1408 to join with housing 1450 (see FIG. 55 for housing 1450). FIG.
54D is a perspective front view of bayonet 1402. FIG. 54E is a side
view of bayonet 1402 that shows lace entry hole 1410 disposed on
inner section 1412 of bayonet 1402. FIG. 54F is an end view of
bayonet 1402 showing entry holes 1410. FIG. 54F also shows the
general arrangement of inner section 1412 and outer section 1414
for a particular embodiment.
[0271] In a preferred embodiment, lace holes mounted on the rear or
inside of bayonet 1402 facilitate lace guides disposed inside the
structure of the footwear. For cosmetic or structural reasons, it
may be valuable to have the lace 23 completely hidden from the
surface of the footwear. As will be understood, lace entry holes
1410 could easily be located at various other positions on inner
section 1412 with similar effects.
[0272] FIGS. 54I through 54K illustrate various views of an
alternative bayonet 1402. This embodiment may preferably be used
for a tongue mounted, front mounted, or midline centered tightening
mechanism or in another location in which it might be advantageous
for the lace 23 to rest on the outer surface of the structure to
which tightening mechanism 1400 is mounted. Side lace entry ports
1410 are located on outer section 1414 of bayonet 1402.
Accordingly, outer section 1414 is deeper than inner section 1412.
Lace exit holes 1408 again allow lace 23 to pass through bayonet
1402 to couple with housing 1450. It is also possible to form
bayonet 1402 with equally deep inner 1412 and outer 1414
sections.
[0273] FIGS. 55A through 55D illustrate one embodiment of housing
1450 coupled to knob assembly 1550. FIG. 55A is a rear view showing
backing plate 1468 secured to housing 1462. In the illustrated
embodiment, backing plate 1468 is removeably secured with screws.
However, in alternative embodiments, one may use any of a number of
other securing means, both removable or permanent, including
rivets, snaps, or pins as will be understood by one of skill in the
art. Backing plate 1468 provides a backing to cavity 1464 in
housing 1462. As shown in FIG. 53, spool 1482 is configured to
mount within cavity 1464 and, in this embodiment, rest against
backing plate 1468. Similarly, plate 1454 is secured to the rear
side of housing 1462 to provide a seat for shaft 1456 (shown in
FIG. 53). The upper surface of housing 1464 is enclosed by cover
1490 which includes access hole 1496 and housing teeth 1492. In a
preferred embodiment, cover 1490 is removeably secured to housing
1462 by a combination of screws 1492 and a lipped flange 1491.
Other securing means may be used as disclosed herein above with
respect to this and other embodiments. Preferably, cover 1490 is
removeably secured to allow access to the inner components of
tightening mechanism 1400, e.g. spool assembly 1480. Such a cover
facilitates replacement of the various components and may ease
replacement of the lace 23 in the housing 1460 and the spool
1480.
[0274] FIGS. 56A through 56D illustrate another embodiment of
housing 1450 coupled to knob assembly 1550 and differ from FIGS.
55A through 55D only in that this illustrated embodiment includes a
coiler assembly 1600. As illustrated in FIG. 53, coiler assembly
consists of a spring boss 1608 positioned in the center of power
spring 1606. Boss 1608 and spring 1606 are positioned within coiler
backing 1604 which is, in turn, secured to housing 1462 by coiler
screws 1602. Coiler assembly 1600 works in a similar fashion to the
coiling systems described herein above. Central boss post 1610
engages centered engagement section 1500 of spool 1482. As such, as
spool 1482 is rotated through interaction with pinion gear 1552 of
knob assembly 1550, so too is the spring boss 1608. As discussed
above, spring boss 1608 is coupled to power spring 1606 such that
pulling lace 23 from spool 1482 biases the spring 1606. When the
lace 23 is released, spring 1606 rotates spool 1482 to take up
excess lace length.
[0275] In a first, also referred to herein as a coupled or an
engaged position (shown in FIGS. 55F and 56F), knob 1550 is
mechanically engaged with an internal gear mechanism located within
housing assembly 1460, as described more fully below. In a second,
also referred to herein as an uncoupled or a disengaged position
(shown in FIGS. 55E and 56E), knob 1550 is disposed upwardly or
outwardly with respect to the first position and is mechanically
disengaged from the gear mechanism. Disengagement of knob 1550 from
the internal gear mechanism is preferably accomplished by pulling
the control mechanism outward, away from mounting flange 1404,
along axis A. Alternatively, the components may be disengaged using
a button or release, or a combination of a button and rotation of
knob 1550, or variations thereof, as will be appreciated by those
of skill in the art and as herein described above.
[0276] Referring now to FIGS. 57A through 57F, elements of the
spool assembly 1480 are shown in greater detail. Spool 1482
includes annular groove 1483. The base of spool 1482 is defined by
cylindrical wall 1481. In many embodiments, spool 1482 includes at
least one lace entry hole 1488, often it includes three or more
holes 1488, and most preferably, it includes two holes 1488. Lace
23 may be removeably secured to spool 1482 with, for example, spool
screws 1484 which pass through spool screw holes 1498 (FIG. 57C).
Though it is preferable for each screw 1484 to secure an individual
lace end, it is also possible for a single screw to secure multiple
lace ends. Other means for releasably securing the lace to the
spool are also envisioned as disclosed above. For example, lace 23
may be tied to spool 1482 as discussed with above in reference to
spool 1240 of tightening mechanism 1200. It is also possible for
lace 23 to be permanently affixed to the spool by welding or the
like as will be appreciated by those of skill in the art.
Releasable laces advantageously allow for replacement of individual
components of tightening mechanism 1400 rather than replacement of
the entire structure to which it is attached. [
[0277] The cylindrical wall 1481 has a diameter of generally less
than about 0.75 inches, often no more than about 0.5 inches, and,
in one embodiment, the diameter of the cylindrical wall 1481 is
approximately 0.4 inches.
[0278] The depth of the annular groove 1483 is generally less than
a 1/2 inch, often less than 3/8 of an inch, and, in certain
embodiments, is no more than about a 1/4 inch. In one embodiment,
the depth is approximately 3/16 of an inch. The width of the
annular groove 1483 at about the opening thereof is generally no
greater than about 0.25 inches, and, in one embodiment, is no more
than about 0.13 inches.
[0279] Spool assembly 1480 preferably includes spool 1482 and main
gear 1486. Main gear 1486 and spool 1482 are shown manufactured
separately and later mechanically attached. Inner attachment teeth
1490 are configured to matingly engage with spool teeth 1491 to
secure main gear 1486 to spool 1482. In alternative embodiments,
main gear 1486 and spool 1482 are manufactured from the same piece.
Spool assembly 1480 may comprise a metal. Alternatively, it may
comprise a nylon or other rigid polymeric material, a ceramic, or
any combination thereof
[0280] Spool screw holes 1498 are located in spool cavity 1495.
Access to holes 1498 is facilitated by access hole 1496 and cover
1490. As such, lace 23 can be released from spool 1482 without
fully disassembling housing 1450. Rather, removal of knob assembly
1550 permits access to access hole 1496. In some embodiments, knob
1560 is sized to allow access to access hole 1496 without removal
of knob assembly 1550.
[0281] Knob assembly 1550 (FIG. 58), preferably includes a cap
1572, a knob screw 1570, a knob 1560, and a pinion gear 1552. When
engaged with knob 1560, cap 1572 loosely secures knob screw 1570
such that screw 1570 remains with knob assembly 1550 when the
assembly is removed from the housing assembly 1450. Cap 1572 may
include indicia 1574 or may present a smooth surface.
Advantageously, cap 1572 includes knob screw access hole 1576 such
that knob screw 1570 may be engaged by an appropriate tool without
removal of cap 1572 from knob 1560. Pinion gear 1552 is configured
to mount within cavity 1564 of knob 1560.
[0282] As shown in FIG. 58, knob 1560 preferably includes pawls
1562 for engagement with housing teeth 1494. Pawls 1562 and housing
teeth 1494 are preferably configured to limit the direction of
rotation of knob 1560. Tightening mechanism 1400 may be
manufactured for right or left handed operation as discussed above
with reference to other embodiments. The illustrated embodiment is
configured for right handed operation. Indicia are used on the
components to ensure that right handed components are used with
other right handed components. Knob 1560 may also include
protrusions 1568 which prevent mounting a right handed knob
assembly on a left handed housing. Gripping surface 1569 of knob
1560 may be manufactured separately or together with knob 1560.
Preferably, an over mold of rubber, or some other friction
enhancing material, is used to provide for increased traction on
the knob 1560.
[0283] Main gear 1486 includes gear teeth 1496 for engagement with
pinion gear teeth 1556. The ratio of the main gear to the pinion
gear is a factor in determining the amount of mechanical advantage
achieved by tightening mechanism 1400. In some embodiments, this
gear ratio will be greater than about 1 to 1, often at least about
about 2 to 1, in one embodiment at least about 3 to 1, and can be
up to between about 4 to 1 or about 6 to 1. In many embodiments of
the present invention, main gear 1486 will have an outside diameter
of at least about 0.5 inches, often at least about 0.75 inches,
and, in one embodiment, at least about 1.0 inches. The outside
diameter of main gear 1486 will generally be less than about 2
inches, and preferably less than about 1.5 inches. In many
embodiments, the pinion gear 1552 with have an outside diameter of
at least about 1/4 inches, often at least about 0.5 inches, and, in
one embodiment, at least about 3/8 inches. The outside diameter of
pinion gear 1552 will generally be less than about 1.0 inches, and
preferably less than about 0.4 inches.
[0284] In many embodiments of the present invention, the knob 1560
will have an outside diameter of at least about 0.75 inches, often
at least about 1.0 inches, and, in one embodiment, at least about
1.5 inches. The outside diameter of the knob 1560 will generally be
less than about 2.25 inches, and preferably less than about 1.75
inches.
[0285] The lace for cooperating with the forgoing cylindrical wall
1481 is generally small enough in diameter that the annular groove
1483 can hold at least about 14 inches, preferably at least about
18 inches, in certain embodiments at least about 22 inches, and, in
one embodiment, approximately 24 inches or more of length,
excluding attachment ends of the lace. At the fully wound end of
the winding cycle, the outside diameter of the cylindrical stack of
wound lace is less than about 100% of the diameter of the knob
1560, and, preferably, is less than about 75% of the diameter of
the knob 1560. In one embodiment, the outer diameter of the fully
wound up lace is less than about 65% of the diameter of the knob
1560.
[0286] Mechanical advantage is achieved by a combination of gear
ratio and the effective spool diameter to knob ratio. This
combination of ratios results in larger mechanical advantage than
either alone while maintaining a compact package. In some
embodiments of the present invention, the combined ratios will be
greater than 1.5 to 1, in one embodiment at least about 2 to 1, in
another about 3 to 1, and in another about 4 to 1. The rations are
generally less than about 7 to 1 and are often less than about 4.5
to 1. [
[0287] The maximum effective spool diameter less than about 75% of
the diameter of the knob 1300 even when the spool is at its fully
wound maximum, maintains sufficient leverage so that gearing or
other leverage enhancing structures are not necessary. As used
herein, the term effective spool diameter refers to the outside
diameter of the windings of lace around the cylindrical wall 1252,
which, as will be understood by those of skill in the art,
increases as additional lace is wound around the cylindrical wall
1252.
[0288] In one embodiment, approximately 24 inches of lace will be
received by 15 revolutions about the cylindrical wall 1252.
Generally, at least about 10 revolutions, often at least about 12
revolutions, and, preferably, at least about 15 revolutions of the
lace around the cylindrical wall 1252 will still result in an
effective spool diameter of no greater than about 65% or about 75%
of the diameter of the knob 1301.
[0289] In general, laces having an outside diameter of less than
about 0.060 inches, and often less than about 0.045 inches will be
used. In certain preferred embodiments, lace diameters of less than
about 0.035 will be used.
[0290] FIGS. 60A and 60B illustrate engaged and non-engaged states
of the housing assembly 1450 and knob assembly 1550. Knob assembly
1550 is mechanically coupled to housing assembly via shaft 1456 and
knob screw 1570. Spring 1458 engages housing 1462 on one end and
shaft cap 1457 on the other. When knob assembly 1550 is coupled to
shaft 1456, spring 1458 biases knob assembly 1550 in the engaged
position such that pawls 1562 of knob 1560 engage housing teeth
1494 of housing cover 1490 and pinion gear teeth 1556 of pinion
gear 1552 engage main gear teeth 1496 of main gear 1486.
[0291] In the non-engaged or disengaged position, shaft cap 1457
engages flange 1466 to secure knob assembly 1550 in the disengaged
position. Pushing knob 1560 back towards housing assembly 1450
disengages flange 1466 and knob assembly 1550 re-engages with
housing assembly 1450. In some embodiments, pawls 1562 remain
engaged with housing teeth 1494 to prevent rotation of the knob
1560 in the reverse direction even in the disengaged position.
However, pinion gear 1552 becomes disengaged from the main gear
1486 in the disengaged position, allowing free rotation of spool
assembly 1480.
[0292] Though discussed in terms of footwear, which includes, but
is not limited to, ski boots, snow boots, ice skates, horseback
riding boots, hiking shoes, running shoes, athletic shoes,
specialty shoes, and training shoes, the closure systems disclosed
herein may also provide efficient and effective closure options in
a number of various different applications. Such applications may
include use in closure or attachment systems on back packs and
other articles for transport or carrying, belts, waistlines and/or
cuffs of pants and jackets, neck straps and headbands for helmets,
gloves, bindings for watersports, snow sports, and other extreme
sports, or in any situation where a system for drawing two objects
together is advantageous.
[0293] Although this invention has been disclosed in the context of
certain preferred embodiments and examples, it will be understood
by those skilled in the art that the present invention extends
beyond the specifically disclosed embodiments to other alternative
embodiments and/or uses of the invention and obvious modifications
and equivalents thereof In addition, while a number of variations
of the invention have been shown and described in detail, other
modifications, which are within the scope of this invention, will
be readily apparent to those of skill in the art based upon this
disclosure. It is also contemplated that various combinations or
subcombinations of the specific features and aspects of the
embodiments may be made and still fall within the scope of the
invention. Accordingly, it should be understood that various
features and aspects of the disclosed embodiments can be combined
with or substituted for one another in order to form varying modes
of the disclosed invention. Thus, it is intended that the scope of
the present invention herein disclosed should not be limited by the
particular disclosed embodiments described above, but should be
determined only by a fair reading of the claims that follow.
* * * * *