US20020095750A1 - Footwear lacing system - Google Patents

Abstract

Disclosed is a footwear lacing system comprising a lace attached to a tightening mechanism. The lace is threaded through a series of opposing guide members positioned along the top of the foot and ankle portions of the footwear. The lace and guide 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. A release mechanism allows a user to quickly loosen the lace.

Description

• This application is a continuation-in-part of U.S. patent application Ser. No. 09/956,601 filed on Sep. 18, 2001 which is a continuation of U.S. patent application Ser. No. 09/388,756 filed on 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 B1 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[0001]
• The present invention relates to footwear. More particularly, the present invention relates to a low-friction lacing system that provides equilibrated tightening pressure across a wearer's foot for sports boots and shoes.[0002]
BACKGROUND OF THE INVENTION
• There currently exists 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 zigzag 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.[0003]
• 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.[0004]
• 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.[0005]
• 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.[0006]
SUMMARY OF THE INVENTION
• 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 opposing cable guide members are positioned on the opposing sides. A single strand nickel-titanium alloy cable is guided by the guide members, the cable having a first end and a second end, with the first and second ends removably secured with respect to a spool. A tightening mechanism is attached to the footwear member, and coupled to the spool, the tightening mechanism including a control for winding the cable around the spool to place tension on the cable thereby pulling the opposing sides towards each other.[0007]
• In one embodiment, the first and second ends are removably connected to the spool such that the cable may be removed from the footwear lacing system without removing the spool. The cable has a diameter within the range of from about 0.020 inches to about 0.040 inches. In certain embodiments, the cable has a diameter within the range of from about 0.025 inches to about 0.035 inches. In one embodiment, the cable comprises a rounded end. The cable may also or alternatively comprise a tapered zone, such that the cross sectional area of the cable decreases in the direction of an end.[0008]
• The cable is slideably positioned around the guide members to provide a dynamic fit in response to movement of the foot within the footwear.[0009]
• As an optional feature, the footwear lacing system further comprises at least one expansion limiting band thereon, which resides in an expansion limiting plane. The expansion limiting band may be positioned on the footwear such that it surrounds the wearer's ankle. The band may reside in a plane which is parallel to or inclined with respect to the sole of the footwear.[0010]
• The tightening mechanism may comprise a rotatable spool or reel for receiving the lace. The reel may additionally comprise a rotatable knob, selectively engageable with the reel. In one application, the knob is only rotatable in a first, lace tightening direction. The knob may be moveable between an engaged position and a disengaged position, and the reel is rotationally locked to the knob when the knob is in the engaged position.[0011]
• As a further option, the reel may be further provided with a tensioning spring, for automatically winding the reel to remove slack from the lace.[0012]
• In accordance with another aspect of the present invention, there is provided a method of balancing tension along the length of a lacing zone in a boot. The method comprises the steps of providing a boot having first and second opposed sets of guide members, and a lace extending back and forth between the first and second opposed guide members. The guide members each define a pathway through which the lace slides, and a rotatable tightening mechanism is provided on the boot for retracting lace thereby advancing the first and second sets of opposed guide members towards each other to tighten the boot. The tightening mechanism is rotated to retract the lace thereby advancing the first and second opposing sets of guide members toward each other to tighten the boot. The lace is permitted to slide through the guide members, to distribute the tightening force along the length of the guide members and to equilibrate tightening force along the length of the lacing zone on the boot. Expansion in at least one plane through the lacing zone is limited by fastening an expansion limiting strap in that plane.[0013]
• Further features and advantages of the present invention will become apparent from the detailed description of preferred embodiments which follows, when considered together with the attached drawings and claims.[0014]
BRIEF DESCRIPTION OF THE DRAWINGS
• FIG. 1 is a side view of a sport boot including a lacing system configured in accordance with the present invention;[0015]
• FIG. 2 is a front view of the sport boot of FIG. 1;[0016]
• FIG. 3 is a perspective schematic view of the lacing system of the sport boot of FIG. 1;[0017]
• FIG. 4A is an exploded perspective view of a multi-piece lace guide member;[0018]
• FIG. 4B is a perspective view of an assembled multi-piece guide member;[0019]
• FIG. 4C is a schematic perspective view of an adjustable guide member in accordance with the present invention;[0020]
• FIG. 5 is a cross-sectional view of the multi-piece guide member of FIG. 4 along line[0021]5-5;
• FIG. 6 is a top plan view of the multi-piece guide member;[0022]
• FIG. 7 is a perspective view of an end portion of a lace having a welded tip;[0023]
• FIG. 8 is an exploded perspective view of one embodiment of a tightening mechanism used with the lacing system described herein;[0024]
• FIG. 9 is a cross-sectional side view of the assembled tightening mechanism of FIG. 8; and[0025]
• FIG. 10 is a cross-sectional view of the tightening mechanism of FIG. 9 taken along the line[0026]10-10;
• FIG. 11 is a side view of the sport boot including an ankle support strap;[0027]
• FIG. 12 is a front view of the sport boot including a central lace guide member disposed adjacent the tongue of the boot;[0028]
• FIG. 13 is a perspective view of the central lace guide member;[0029]
• FIG. 14 is a cross-sectional view taken along the line[0030]14-14 in FIG. 13;
• FIG. 15 is a schematic front view of the instep portion of the boot with a plurality of lace locking members disposed along the lace pathway;[0031]
• FIG. 16 is a side view of one embodiment of a lace locking member engaged with the boot lace;[0032]
• FIG. 17 is a side view of one embodiment of a lace locking member non-engaged with the boot lace;[0033]
• FIG. 18 is a side view of a second embodiment of the lace locking member;[0034]
• FIG. 19 is a top plan view of a first member portion of the lace locking member of FIG. 18;[0035]
• FIG. 20 is a front view of the instep portion of the boot;[0036]
• FIG. 21 is an enlarged view of the region within[0037]line21 of FIG. 20;
• FIG. 22 is a top plan view of an alternative embodiment of a lace guide;[0038]
• FIG. 22A is a perspective view of a guide tube stop in accordance with the present invention;[0039]
• FIG. 23 is a top plan view of an alternative embodiment of a lace guide;[0040]
• FIG. 24 is a side view of the lace guide of FIG. 23;[0041]
• FIG. 25 is a top view of the lace guide of FIG. 23 mounted in a boot flap;[0042]
• FIG. 26 is a cross-sectional view of the lace guide and boot flap along line[0043]26-26 of FIG. 25;
• FIG. 27 is a side view of a second embodiment of the tightening mechanism;[0044]
• FIG. 27A is a top plan view of a mounting ring for a releasable bayonet mounting in accordance with one aspect of the present invention.[0045]
• FIG. 28 is a cross-sectional view of the embodiment of FIG. 27;[0046]
• FIG. 29 is a cross-sectional view of an alternate tightening mechanism.[0047]
• FIG. 30 is a split elevational cross section through a tightening mechanism, with the left side in the coupled position and the right side in the uncoupled position.[0048]
• FIG. 31 is a cross section through a knob, showing integrally molded pawls.[0049]
• FIG. 32 is a cross section through a tightening mechanism case, illustrating ratchet teeth on the case.[0050]
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
• Referring to FIG. 1, there is disclosed one embodiment of a[0051]sport boot20 prepared in accordance with the present invention. Thesport boot20 generally comprises an ice skating or other action sport boot which is tightened around a wearer's foot using alacing system22. Thelacing system22 includes a lace23 (FIG. 2) that is threaded through theboot20 and attached at opposite ends to atightening mechanism25, as described in detail below. As used herein, the terms lace and cable have the same meaning unless specified otherwise. Thelace23 is a low friction lace that slides easily through theboot20 and automatically equilibrates tightening of theboot20 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.
• The[0052]boot20 includes an upper24 comprising atoe portion26, aheel portion28, and anankle portion29 that surrounds the wearer's ankle. Aninstep portion30 of the upper24 is interposed between thetoe portion26 and theankle portion29. Theinstep portion30 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 blade31 (shown in phantom lines) extends downward from the bottom of theboot20 in an ice-skating embodiment.
• FIG. 2 is a front elevational view of the[0053]boot20. As shown, the top of theboot20 generally comprises two opposed closure edges or flaps32 and34 that partially cover atongue36. Generally, thelace23 may be tensioned to draw theflaps32 and34 toward each other and tighten theboot20 around the foot, as described in detail below. Although the inner edges of theflaps32 and34 are shown separated by a distance, it is understood that theflaps32 and34 could also be sized to overlap each other when theboot20 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.
• Referring to FIG. 2, the[0054]tongue36 extends rearwardly from thetoe portion26 toward theankle portion29 of theboot20. Preferably, thetongue36 is provided with a low frictiontop surface37 to facilitate sliding of theflaps32 and34 andlace23 over the surface of thetongue32 when thelace23 is tightened. Thelow friction surface37 may be formed integrally with thetongue32 or applied thereto such as by adhesives, heat bonding, stitching or the like. In one embodiment, thesurface37 is formed by adhering a flexible layer of nylon or polytetrafluoroethylene to the top surface of thetongue36. Thetongue36 is preferably manufactured of a soft material, such as leather.
• The upper[0055]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 upper24 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 upper24 may be manufactured of a hard or soft plastic. It is also contemplated that the upper24 could be manufactured from any of a variety of other known materials.
• As shown in FIG. 2, the[0056]lace23 is threaded in a crossing pattern along the midline of the foot between two generally parallel rows ofside retaining members40 located on theflaps32 and34. In the illustrated embodiment, theside retaining members40 each consist of a strip of material looped around the top and bottom edges of theflaps32 and34 so as to define a space in which guides50 are positioned. Thelace23 slides through theguides50 during tightening and untightening of thelace23, as described more fully below. In the illustrated embodiment, there are threeside retaining members40 on eachflap32,34 although the number of retainingmembers40 may vary. In some embodiments, four, five or six ormore retaining members40 may be desirable on each side of the boot.
• 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[0057]side retaining members40 each consist of a strip of material looped around theguides50. Additional adjustability may be achieved by providing a releasable attachment between theside retaining members40 and thecorresponding flap32 or34 of the shoe. In this manner, theside retaining member40 may be moved laterally away from the midline of the foot to increase the distance between opposing lace guides.
• One embodiment of the adjustable[0058]side retaining member40 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 thecorresponding flap32 or34 using conventional means such as rivets, stitching, adhesives, or others known in the art. The strip of material loops around theguide50, and is folded back over the outside of thecorresponding flap32 or34 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®), or other releasable engagement locks or clamps which permits lateral-medial adjustability of the position of theguide50 with respect to the edge of thecorresponding flap32 or34.
• The[0059]guides50 may be attached to theflaps32 and34 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 retainingmembers40 can be deleted and theguide50 sewn directly onto the surface of theflap32 or34 or opposing sides of the upper. Stitching theguide50 directly to theflap32 or34 may advantageously permit optimal control over the force distribution along the length of theguide50. For example, when thelace23 is under relatively high levels of tension, theguide50 may tend to want to bend and to possibly even kink near the curved transition in betweenlongitudinal portion51 andtransverse portion53 as will be discussed. Bending of the guide member under tension may increase friction between the guide member and thelace23, and, severe bending or kinking of theguide member50 may undesirably interfere with the intended operation of the lacing system. Thus, the attachment mechanism for attaching theguide member50 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 theguide member50.
• As shown in FIGS. 1 and 2, the[0060]lace23 also extends around theankle portion29 through a pair of upper retainingmembers44aand44blocated on theankle portion29. Theupper retaining members44aand44beach comprise a strip of material having a partially raised central portion that defines a space between the retaining members44 and the upper24. Anupper guide member52 extends through each of the spaces for guiding thelace23 around either side of theankle portion29 to thetightening mechanism25.
• FIG. 3 is a schematic perspective view of the[0061]lacing system22 of theboot20. As shown, each of the side andtop guide members50 and52, has a tube-like configuration having acentral lumen54. Eachlumen54 has an inside diameter that is larger than the outside diameter of thelace23 to facilitate sliding of thelace23 through the side andtop guide members50,52 and prevent binding of thelace23 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 thelumen54 can be varied to fit specific desired lace dimensions and other design considerations. The wall thickness and composition of theguides50,52 may be varied to take into account the physical requirements imposed by particular shoe designs.
• Thus, although the[0062]guides50 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.) flaps40 may be utilized to hold down any of a variety of guide structures. In one embodiment, theguide50 is a molded block having a lumen extending therethrough. This may take a form similar to that illustrated in FIGS. 4A, 4B or6. 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. 6, such that the overall part has a shallow “U” shaped configuration which allows it to be conveniently retained by theretention structure40. Providing aguide member50 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 guides50 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.
• In general, each of the[0063]guide members50 and52 defines a pair ofopenings49 that communicate with opposite ends of thelumen54. Theopenings49 function as inlets/outlets for thelace23. The openings desirably are at least as wide as the cross-section of thelumen54.
• As may be best seen in FIG. 3, each[0064]top guide52 has anend55 which is spaced apart from acorresponding side guide50 on the opposing side of the footwear, with thelace23 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 theside guide50 andtop guide52 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 oflace23 between acorresponding end55 oftop guide52 andside guide50. 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 thelace23 in-between thetop guide52 andside guide50. Further tightening of the system will thus not be able to draw thetop guide52 and corresponding side guide50 any closer together.
• The stop may be constructed in any of a variety of ways, such that it may be removably positioned between the[0065]top guide52 and side guide50 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 thelace23, as will be apparent to those of skill in the art. A selection of lengths may be provided, such as ½ inch, 1 inch, 1½ 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 ¼ inch may also be utilized, if desired.
• In FIG. 3, the[0066]top guide52 is illustrated for simplicity as unattached to thecorresponding side flap32. However, in an actual product, thetop guide52 is preferable secured to theside flap32. For example, upper retainingmember44a, discussed above, is illustrated in FIG. 2. Alternatively, thetop guide52 may extend within the material of or between the layers of theside flap32. As a further alternative, or in addition to the foregoing, theend55 oftop guide52 may be anchored to theside flap32 using any of a variety of tie down or clamping structures. One suitable structure is illustrated in FIG. 22a, discussed below. Thelace23 may be slideably positioned within a tubular sleeve extending between the reel and the tie down at theend55 of the sleeve.
• 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[0067]lace23 between the reel and the tie down at theend55 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 in addition to that illustrated in FIG. 22A, 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.
• In the illustrated embodiment, the[0068]side guide members50 each have a generally U-shape that opens towards the midline of the shoe. Preferably, each of theside guide members50 comprise alongitudinal portion51 and two inclined ortransverse portions53 extending therefrom. The length of thelongitudinal portion51 may be varied to adjust the distribution of the closing pressure that thelace23 applies to the upper24 when thelace23 is under tension. In addition, the length of thelongitudinal portion51 need not be the same for allguide members50 on a particular shoe. For example, thelongitudinal portion51 may be shortened near theankle portion29 to increase the closing pressure that thelace23 applies to the ankles of the wearer. In general, the length of thelongitudinal portion51 will fall within the range of from about ½″ to about 3″, and, in some embodiments, within the range of from about ¼″ to about 4″. In one snowboard application, thelongitudinal portion51 had a length of about 2″. The length of thetransverse portion53 is generally within the range of from about ⅛″ to about 1″. In one snowboard embodiment, the length oftransverse portion53 was about ½″. 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.
• In between the[0069]longitudinal portion51 andtransverse portion53 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 thelace23 can slide, as it rounds the comer. Thetransverse section53 can in some embodiments be deleted, as long as a rounded cornering surface is provided to facilitate sliding of thelace23. In an embodiment which has atransverse section53 and a radiused transition, with aguide member50 having an outside diameter of 0.090″ and alace23 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″.
• Referring to FIG. 3, the[0070]upper guide members52 extend substantially around opposite sides of theankle portion29. Eachupper guide member52 has aproximal end56 and adistal end55. The distal ends55 are positioned near the top of thetongue36 for receipt of thelace23 from the uppermostside guide members50. The proximal ends56 are coupled to thetightening mechanism25. In the illustrated embodiment, the proximal ends56 include rectangular coupling mounts57 that engage with thetightening mechanism25 for feeding the ends of thelace23 therein, as described more fully below. Theguide members50 and/or52 are preferably manufactured of a low friction material, such as a lubricous polymer or metal, that facilitates the slideability of thelace23 therethrough. Alternatively, theguides50,52 can be made from any convenient substantially rigid material, and then be provided with a lubricous coating on at least the inside surface oflumen54 to enhance slideability. Theguide members50 and52 are preferably substantially rigid to prevent bending and kinking of theguide members50,52 and/or thelace23 within any of theguide members50 and52 as thelace23 is tightened. Theguide members50,52 may be manufactured from straight tube of material that is cold bent or heated and bent to a desired shape.
• Alternatively, the[0071]guide members50,52 may be constructed in a manner that permits bending, retains a low friction surface, yet resist kinking. For example, guidemembers50,52 may comprise a spring coil, either with the spring coil exposed or the spring coil provided with a polymeric coating on the inside surface or outside surface or both. The provision of a spring coil guide satisfies the need for lateral flexibility in some embodiments, yet retains a hard interior surface which help to minimize friction between the guide and the lace.
• As an[0072]alternate guide member50,52 design which increases lateral flexibility yet retains a hard interior lace contacting surface, theguide50 may comprise a plurality of coaxially-aligned segments of a hard polymeric or metal tube material. Thus, a plurality of tubing segments, each segment having an axial length within the range of from about 0.1″ to about 1.0″, and preferably about 0.25″ or less can be coaxially aligned, either in end-to-end contact or axially spaced apart along the length of theguide50,52. Adjacent tubular segments can be maintained in a coaxial relationship such as by the provision of an outer flexible polymeric jacket. The shape of the tubular guide may be retained such as by stitching the guide onto the side of the shoe in the desired orientation, or through other techniques which will be apparent to those of skill in the art in view of the disclosure herein.
• As an alternative to the previously described tubular guide members, the[0073]guide members50 and/or52 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.
• 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.[0074]
• As an alternative to the previously described tubular guide members, the[0075]guide members50 and/or52 comprise amulti-piece guide member199 comprised of afirst member200 and asecond member202 that mates thereto, such as shown in FIGS. 4A and 4B. Thefirst member200 and thesecond member202 each have a thin, flat shape. A cavity or seat204 (FIG. 4A) extends into an upper surface of thefirst member200. Theseat204 is preferably sized to receive thesecond member202 snug therein, such as in a press-fit fashion, as best shown in FIG. 4B.
• As shown in the cross-sectional view of FIG. 5, the[0076]second member202 may be positioned within the seat so that agap206 of predetermined shape is defined between thesecond member202 and thefirst member200. A pair of apertures207 (FIGS. 4A, 4B) are located on one of the first orsecond member202,204 to serve as entryways into thegap206. Theapertures207 preferably are sufficiently large to allow passage of thelace23 therethrough. In one embodiment, theapertures207 are within the range of from about 0.030 inches to about 0.060 inches in diameter.
• With reference to FIG. 6, the[0077]gap206 is elongated so that it defines a lace pathway that functions as thelumen54 for thelace23. Thelumen54 preferably includes anelongate region209 that extends generally lengthwise along the edges of theflaps32 or34 when theguide member199 is mounted on the boot. Theelongate region209 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, theelongate region209 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. Thelumen54 further includes atransverse region210 on opposite ends of theelongate region209. Thetransverse region210 extends at an incline to the edges of theflaps32 and34. Alternatively, theelongate region209 and thetransverse region210 may be merged into one region having a continuous circular or elliptical profile to spread load evenly along the length of thelumen54 and thereby reduce total friction in the system.
• The first and[0078]second members200,202 of themulti-piece guide member199 may be manufactured of a low friction material, such as a lubricous polymer or metal, that facilitates the slideability of thelace23 therethrough. Alternatively, theguide member199 can be made from any convenient substantially rigid material, and then be provided with a lubricous coating on at least the surface of the inside curve oflumen54 to enhance slideability. Theguide member199 may be substantially rigid to prevent bending and kinking of theguide member199 and/or thelace23 therein as thelace23 is tightened. Theguide member199 may alternatively be made of a flexible material when used in portions of the shoe that are subject to bending. Theguide members50,52 may be manufactured through known molding processes.
• Referring to FIG. 4A, each of the[0079]guide members199 has a predetermined distance between the first opening207aand second opening207bto 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. An embodiment in which the distance between the first opening207aand second opening207bis adjustable is illustrated schematically in FIG. 4C. Any of a wide variety of other implementations may be readily devised, which incorporate the function of the structure schematically illustrated in FIG. 4C.
• In general, a[0080]first guide element211 is spaced apart from asecond guide element213. Thefirst guide element211 contains a first partial or complete aperture207afor receivinglace23 therethrough. Thesecond guide element213 includes the second partial or complete aperture207b, also for receiving thelace23 therethrough. As is the case with other embodiments herein, the lace pathway (not illustrated) through the first andsecond guide elements211 and213 may extend through a tunnel or may extend along a curved surface, such as a rotatable pulley, radiused recess or otherwise depending upon the desired performance and construction.
• As illustrated in FIG. 4C, the[0081]lace23 enters the first aperture207a, extends through thefirst guide element211, and into thesecond guide element213. Theadjustable guide member199 is additionally provided with a threadedshaft215 extending between the first andsecond guide elements211 and213. Rotation of the threadedshaft215 in a first direction draws theguide elements211 and213 towards each other, thereby shortening the distance between the lace apertures207aand207b. Rotating the threadedshaft215 in an opposite direction increases the axial distance between apertures207aand207b. Specific rotational engagements between the threadedshaft215, guideelements211 and213, to accomplish this purpose are well known in the art. A rotatable engagement structure, such as a slotted head, a hex recess or projection, or the like may be provided on oneend217 of the threadedshaft215. Any of a variety of alternate structures may be utilized, to permit the adjustment of the spacing between the apertures207aand207b, as will be apparent to those of ordinary skill in the art in view of the disclosure herein.
• The[0082]lace23 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, thelace23 comprises a stranded cable, such as a 7 strand by 7 strand cable manufactured of stainless steel. In order to reduce friction between thelace23 and theguide members50,52 through which thelace23 slides, the outer surface of thelace23 is preferably coated with a lubricous material, such as nylon or Teflon. In a preferred embodiment, the diameter of thelace23 ranges from 0.024 inches to 0.060 inches and is preferably 0.027 inches. Thelace23 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. Alace23 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.
• The[0083]lace23 may be formed by cutting a piece of cable to the desired length. If thelace23 comprises a braided or stranded cable, there may be a tendency for the individual strands to separate at the ends or tips of thelace23, thereby making it difficult to thread thelace23 through the openings in theguide members50,52. As thelace23 is fed through the guide members, the strands of thelace23 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 thelace23 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.
• With reference to FIG. 7, one solution to this problem is to provide the tips or ends[0084]59 of thelace23 with a sealed or bondedregion61 wherein the individual strands are retained together to prevent separation of the strands from one another. For clarity of illustration, the bondedregion61 is shown having an elongate length. However, the bondedregion61 may also be a bead located at just the extreme tip of thelace23 and, in one embodiment, could be a bonded tip surface as short as 0.002 inch or less.
• The bonded[0085]region61 may be formed, for example, by applying a weld (e.g., solder tip, brazing, welding, or melting the strands together) to theends59 during formation of thelace23 to thereby hold the strands together and prevent separation of the strands. A tip weld advantageously does not significantly increase the overall diameter of thelace23. Additionally, the weld may also be used to smooth theends59 of thelace23 to facilitate insertion of thelace23 into the guide members. A weld is also advantageous in that it provides a secure, permanent bond between the strands of thelace23. The bondedregion61 provides the ends of thelace23 with a smooth and secure surface that greatly facilitates threading of the lace through the guide members and into the tightening mechanism. The bonded region thus makes it much easier for a user to replace thelace23 in the system. Alternatively, adhesives or thin walled shrink wrap tubing may be used in certain embodiments.
• After the 7×7 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 1×7 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 1×7 cable made with that strand has an 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 1×7 construction and in certain embodiments a 1×3 construction may be utilized.[0086]
• In a 1×3 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.[0087]
• 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 therefor 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.[0088]
• 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.[0089]
• 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 ½ 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.[0090]
• 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.[0091]
• 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° to about 25°, and, in one embodiment about 15°. The angle includes approximately the distal ⅛ 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.[0092]
• 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.[0093]
• 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.[0094]
• As shown in FIG. 3, the[0095]tightening mechanism25 is mounted to the rear of the upper24 byfasteners64. Although thetightening mechanism25 is shown mounted to the rear of theboot20, it is understood that thetightening mechanism25 could be located at any of a wide variety of locations on theboot20. In the case of an ice skating boot, the tightening mechanism is preferably positioned over a top portion of thetongue36. Thetightening mechanism25 may alternatively be located on the bottom of the heal 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 thetightening mechanism25 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 thetightening mechanism25 can be varied widely, depending upon the gear train design, and the desired end use and location on the boot. A relatively lowprofile tightening mechanism25 is generally preferred. The mounted profile of thetightening mechanism25 can be further reduced by recessing thetightening mechanism25 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 ¾″ or more in some locations and for some boots, or on the order of about ⅛″ or ½″ for other location and/or other boots, without adversely impacting the comfort and functionality of the boot.
• In general, the[0096]tightening mechanism25 comprises a control such as a lever, crank or knob, which can be manipulated to retractlace23 therein. In addition, the tightening mechanism preferably comprises a release such as a button or lever, for disengaging the tightening mechanism to permit thelace23 to be withdrawn freely therefrom.
• The[0097]tightening mechanism25 in the illustrated embodiment generally comprises arectangular housing60 and acircular knob62 rotatably mounted thereto. Theknob62 may be rotated to wind the ends of thelace23 into thehousing60 and thereby tension thelace23 to reduce slack. As the slack in thelace23 reduces, thelace23 pulls theside guide members50, and thereby theflaps32 and34, toward the midline of the boot to tighten the upper24 around a foot.
• The[0098]tightening mechanism25 advantageously includes an internal gear mechanism to allow the wearer to easily turn theknob62 to retract thelace23. Preferably, the gear mechanism is configured to incrementally pull and retain a predetermined length of lace as theknob62 is rotated, as described in detail below. A user may thus advantageously continuously adjust the tension in thelace23 to a desired comfort and performance level. Theknob62 may be rotated either manually or through the use of a tool or small motor attached to theknob62.
• Any of a variety of known mechanical structures can be utilized to permit winding of the spool to increase tension on the lace, yet resist unwinding of the spool until desired. For example, any of a wide variety of ratchet structures can be used for this purpose. Alternatively, a Sprague clutch or similar structure will permit one-way rotation of a shaft while resisting rotation in the opposite direction. These and other structures will be well known to those of ordinary skill in the mechanical arts.[0099]
• A[0100]release lever63 is located along a side of thehousing60. The release lever may be rotated to disengage the internal gear mechanism to release tension in thelace23 and loosen the upper23 around the wearer's foot, as described in detail below. This advantageously allows a user to quickly and easily untighten the lacing system by simply turning therelease lever63.
• The low friction relationship between the[0101]lace23 and cable guides50,52 greatly facilitate tightening and untightening of thelacing system20. Specifically, because thelace23 and cable guides50 and52 are manufactured or coated with a low friction material, thelace23 slides easily through the cable guides without catching. Thelace23 thus automatically distributes the tension across its entire length so that tightening pressure is evenly distributed along the length of the ankle and foot. When the tension in thelace23 is released by actuating the release lever, thelace23 slides easily through the cable guides50 and52 to release tension and evenly distribute any slack among the length of the lace. Thelow friction tongue36 also facilitates moving of theflaps32,34 away from each other when thelace23 is loosened.
• FIG. 8 is an exploded perspective view of the various components of one embodiment of the[0102]tightening mechanism25. As shown, thehousing60 consists of a pair of interlockinghalves64aand64bthat are mated to each other usingfasteners66, such as screws. Thehousing60 encloses agear mechanism70 that preferably rotatably fits withincavities65 in the inner surfaces of thehalves64aand64b. In the illustrated embodiment, thegear mechanism70 comprises first, second, andthird gear wheels72,74, and76, respectively, that rotatably engage with each other when the tighteningmechanisms25 is assembled.
• As shown in FIG. 8, the[0103]first gear wheel72 includes ashaft78 about which the first gear wheel rotates. A first portion of theshaft78 extends through an aperture in the housing halve64a. A second portion of theshaft78 extends through an aperture in thehalve64b. Theknob62 mounts to theshaft78 through a mountinghole80 in theknob62. A mountingpin76 removably secures theknob62 to theshaft78 in a well known manner. When thetightening mechanism25 is assembled, rotation of theknob62 causes thefirst gear wheel72 to also rotate. Actuation of thegear mechanism70 is thus accomplished through rotation of theknob62.
• Referring to FIG. 8, the[0104]first gear wheel72 also includes aratchet section82 having a plurality of sloped teeth83 (FIG. 10) positioned circumferentially around the axis of thefirst gear wheel72. The slopedteeth83 are configured to mate with apawl84 to prevent undesired backward rotation of thefirst gear wheel72, as described more fully below. Toward this end, a biasingmember86 couples to apeg90 that extends from thepawl84. The biasingmember86 biases thepawl84 against the ratchet teeth when thegear mechanism70 is assembled. Thethird gear wheel72 also includes agear section92 having a series of gear teeth that extend around the periphery of thethird gear wheel72.
• As shown in FIG. 8, the[0105]second gear wheel74 includes afirst gear section94 and a steppedsecond gear section96 having a diameter smaller than thefirst gear section94 on a common axis of rotation. Thefirst gear section94 has gear teeth that are configured to mesh with thegear section92 of thefirst gear wheel72. Anaperture97 extends centrally through thesecond gear wheel74. Theaperture97 is sized to rotatably receive apost98 that extends from the housing halve64b. Thesecond gear wheel74 rotates about thepost98 during actuation of the assembledgear mechanism70.
• Referring to FIG. 8, the[0106]third gear wheel76 includes agear section100 that is configured to mesh with thesecond gear section96 of thesecond gear wheel74. The third gear wheel also includes aspool section102 comprisinggrooves104,106 that extend around the periphery of thethird gear wheel76. Thegrooves104,106 are sized to receive opposite ends of thelace23 in a winding fashion during actuation of thegear mechanism25.
• The ends[0107]107 and108 of thelace23 are each provided withanchors109 that mate withseating holes110 in a press fit fashion. The seating holes110 are diametrically positioned on thethird gear wheel76. When theanchors109 are mated with the seating holes110, theends107 and108 of thelace23 are separately positioned within thegrooves104 and106, respectively. The coupling mounts57 fit into a corresponding aperture in the housing halve64 to maintain the distal ends56 of theguide member50 in a fixed position relative to the tightening mechanism.
• 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. For example, only a single groove spool can be utilized. However, a dual groove spool or two side-by-side spools as illustrated has the advantage of permitting convenient simultaneous retraction of both lace ends[0108]107 and108. In the illustrated embodiment, withends107 and108 approaching the spool from opposite directions, the lace conveniently wraps around the spool in opposite directions using a single rotatable shaft as will be apparent from FIG. 8.
• 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.[0109]
• Preferably, the[0110]cavity65 is toleranced to fit closely around the outer circumference of the spool, to capture the lace. Thus, the gap between the outer flange walls surrounding each groove and the interior surface of thecavity65 are preferably smaller than the diameter of the lace. hi this manner, the risk of tangling the lace within the winding mechanism can be minimized.
• 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.[0111]
• 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.[0112]
• Rotation of the[0113]third gear wheel76 causes theends107 and108 of thelace23 to wind around thegrooves104 and106, respectively, and thereby pull the length of thelace23 into thetightening mechanism25 and place thelace23 in tension. It is understood that the ends107,108 of thelace23 wind around thespool section102 at an equal rate so that tension is evenly applied to both ends of thelace23.
• The third gear wheel includes a central aperture[0114]111 sized to rotatably receive theshaft78 on thefirst gear wheel72. Thethird gear wheel76 rotates about theshaft78 during actuation of thegear mechanism70.
• In a preferred embodiment, the[0115]third gear wheel76 has a diameter of 0.625 inches. Thesecond gear section96 of thesecond gear wheel74 preferably has a diameter of approximately 0.31 inches and the first gear section preferably has a diameter approximately equal to the diameter of thethird gear wheel76. Thefirst gear wheel72 preferably has a diameter of approximately 0.31 inches. Such a relationship in the gear sizes provides sufficiently small adjustments in the tension of thelace23 as the gear wheels are turned.
• FIG. 9 illustrates a cross-sectional view of the assembled[0116]tightening mechanism25. As shown, theshaft78 of thefirst gear wheel72 is journaled withinapertures112 and114 in thehousing halves64aand64b, respectively. Theknob62 is mounted over the portion of theshaft78 extending out of the halve64athrough theaperture112. The first, second, andthird gear wheels72,74, and76, respectively are in meshed engagement with each other. Specifically, thegear section92 of thefirst gear wheel72 is in meshed engagement with thefirst gear section94 on the second gear wheel. Likewise, thesecond gear section96 on thesecond gear wheel94 is in meshed engagement with thegear section100 of thethird gear wheel76. Accordingly, rotation of theknob62 causes thefirst gear wheel72 to rotate and thereby cause the second gear wheel to rotate in an opposite direction by means of the meshed engagement between thegear sections92 and94. This in turn causes thethird gear wheel76 to rotate in the direction of knob rotation by means of the meshed engagement between thegear sections96 and100.
• As the[0117]third gear wheel76 rotates, theends107 and108 of the lace are wound within thegrooves104 and106 respectively. Rotation of theknob62 thus winds thelace23 around thethird gear wheel76 to thereby tighten theboot20.
• As illustrated, counterclockwise rotation (relative to FIG. 10) of the[0118]knob62 tightens thelace23. The tension in thelace23 is maintained by means of a ratchet mechanism that is described with reference to FIG. 10.
• FIG. 10 is a cross-sectional view of the[0119]tightening mechanism25 taken along the line10-10 of FIG. 9. As shown, the biasingmember86 maintains thepawl84 in locked engagement with the slopedteeth83 on theratchet section82. Thepawl84 thus inhibits clockwise rotation of theknob62 and loosening of thelace23. It will be understood that the slopedteeth83 do not inhibit counterclockwise rotation of theknob62 because thepawl84 slides over theteeth83 when theknob64 is rotated clockwise. As theknob62 is rotated counterclockwise, thepawl84 automatically engages each of theteeth83 to advantageously allow the user to incrementally adjust the amount oflace23 that is drawn into thetightening mechanism25.
• As shown in FIG. 10, the[0120]release lever63 communicates with thepawl84 through ashaft116 that extends through thehousing60. A lower end of theshaft116 is provided with acam member118. Therelease lever63 may be rotated about theshaft116 to cause thecam member118 to also rotate and push thepawl84 away from engagement with theratchet teeth83. When thepawl84 disengages from the ratchet teeth, thefirst gear wheel72, and each of theother gear wheels74 and76, are free to rotate.
• When the user actuates the[0121]release lever63, the tension, if any, in thelace23 causes thelace23 to automatically unwind from thespooling section102. Therelease lever63 is thus used to quickly untighten theboot20 from around the foot. It will be appreciated that the low friction relationship between thelace23 and theguide members50 and52 facilitates sliding of thelace23 within the guide members so that the lace untightens quickly and smoothly by simply turning therelease lever63 and then manually pulling thetongue36 forward.
• It is contemplated that a limit on the expansion of portions of the boot due to the sliding of the[0122]lace23 could be accomplished such as through one or more straps that extend transversely across theboot20 at locations where an expansion limit or increased tightness or support are desired. For instance, a strap could extend across theinstep portion30 from one side of theboot20 to another side of the boot. A second or lone strap could also extend around theankle portion29.
• With reference to FIG. 11, an[0123]expansion limiting strap220 is located on the ankle portion of theboot20 to supplement the closure provided by thelace23 and provide a customizable limit on expansion due to the dynamic fit achieved by the lacing system of the present invention. Thelimit strap220 may also prevent or inhibit the wearer's foot from unintentionally exiting theboot20 if thelace20 is unlocked or severed or the reel fails. In the illustrated embodiment, thestrap220 extends around the ankle of the wearer. The location of thelimit strap220 can be varied depending upon boot design and the types of forces encountered by the boot in a particular athletic activity.
• For example, in the illustrated embodiment, the[0124]limit strap220 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 valve 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 thelimit strap220 may be accomplished by on 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. 11. 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, and may be particularly useful where the reel is provided with a quick mount release such the bayonet mount described in connection with FIG. 27A, discussed below.
• In an alternative design, the expansion limiting plane is positioned in a generally vertical orientation, such as by positioning the[0125]limit strap220 across the top of the foot anterior of the ankle, to achieve a different limit on dynamic fit. In this location, theexpansion limiting strap220 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.
• The[0126]limit strap220 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 250 to about 750 from the plane on which the sole of the boot resides. Positioning thelimit strap220 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.
• The[0127]strap220 preferably includes a fastener222 that could be used to adjust and maintain the tightness of thestrap220. Preferably, the fastener222 is capable of quick attachment and release, so that the wearer can adjust thelimit strap220 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.
• The[0128]strap220 is particularly useful in the present low-friction system. Because thelace23 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.
• 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[0129]strap220 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.
• For example, if the wearer of the boot in FIG. 11 did not have the[0130]ankle strap220, 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 thestrap220 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 thestrap220 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.
• 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.[0131]
• The[0132]footwear lacing system20 described herein advantageously allows a user to incrementally tighten theboot20 around the user's foot. Thelow friction lace23 combined with the lowfriction guide members50,52 produce easy sliding oflace23 within theguide members50 and52. Thelow friction tongue36 facilitates opening and closure of theflaps32 and34 as the lace is tightened. Thelace23 equilibrates tension along its length so that thelacing system23 provides an even distribution of tightening pressure across the foot. The tightening pressure may be incrementally adjusted by turning the knob on thetightening mechanism25. A user may quickly untighten theboot20 by simply turning therelease lever63 or lifting or pressing the knob or operating any alternative release mechanism to automatically release thelace23 from thetightening mechanism25.
• As illustrated in FIG. 12, at least one[0133]anti-abrasion member224 is disposed adjacent thetongue36 and between theflaps32,34. As best shown in FIGS.13, theanti-abrasion member224 comprises a flat disc-like structure having a pair of internal channels orlumen127a, barranged in a crossing pattern so as to define acrossing point230. Thelumen127a, bare sized to receive thelace23 therethrough. As shown in the cross-sectional view of FIG. 14, thelumen127a, bare arranged to prevent contact between adjacent sections of thelace23 at thecrossing point230. Theanti-abrasion member224 thereby prevents chafing of thelace23 at thecrossing point230. Theanti-abrasion member224 also shields thelace23 from thetongue36 to inhibit thelace23 from chafing or abrading thetongue36.
• The[0134]anti-abrasion member224 may alternatively take the form of a knife edge or apex for minimizing the contact area between thelace23 and theanti-abrasion member224 For example, at a crossing point wherelace23crosses tongue36, an axially extending (e.g. along the midline of the foot or ankle) ridge or edge may be provided in-between theboot tongue36 and thelace23. Thisanti-abrasion member224 is preferably molded or otherwise formed from a lubricious plastic such as PTFE, or other material as can be determined through routine experimentation. Thelace23 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 theanti-abrasion member224 would ensure that theanti-abrasion member224 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 lace crossing 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. Theanti-abrasion member224 may be formed integrally with or attached to the tongue or could float on top of the tongue as in previously described disks.
• In one embodiment, the[0135]anti-abrasion member224 is fixedly mounted on thetongue36 using any of a wide variety of well known fasteners, such as rivets, screws, snaps, stitching, glue, etc. In another embodiment, theanti-abrasion member224 is not attached to thetongue36, but rather freely floats atop thetongue36 and is held in place through its engagement with thelace23. Alternatively, theanti-abrasion member224 is integrally formed with thetongue36, such as by threading a first portion of thelace23 through the tongue, and the second, crossing portion oflace23 over the outside surface of the tongue.
• Alternatively, one or more of the sections of[0136]lace23 which extend between theflaps32 and34 may slideably extend through a tubular protective sleeve. Referring to FIG. 12, three crossover points are illustrated, each crossover point including a first and a second crossing segments of thelace23. 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 oflace23 at the central crossover point which, in FIG. 12, is illustrated as carrying theanti-abrasion member24. 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.
• 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[0137]flaps32 and34 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 opposingflaps32 and34 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 thelace23. At least a second tubular sleeve having a second, greater diameter is also carried by thelace23. 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.
• FIG. 15 schematically illustrates a top view of the insole region of the[0138]boot20. At least one lace locking member232 (shown schematically) is disposed along the pathway of thelace23. Each lockingmember232 is configured to engage thelace23 and prevent a predetermined portion of the lace from moving axially, such as toward thetightening mechanism25 to thereby limit the tension of the lace in a predetermined region. For example, a pair of lockingmembers232aare located at points “a” along the lace pathway near the toe region of theflaps32,34. After tension has been applied to thelace23 via thetightening mechanism25, the lockingmembers232amay be engaged with thelace23 to prevent movement of the lace in region “a”. Once engaged, the lockingmembers232asecure the tension in thelace23 in region “a” by locking the position of thelace23 at points “aa” with respect to thetightening mechanism25. The lace tension in region “a” is thereby maintained even if the tension applied to thelace23 by thetightening mechanism25 is released or actuated. Thereafter, thetightening mechanism25 may be released or actuated to apply a different level of tension or tightness in the lace outside of lace region “a”.
• With reference to FIG. 15, locking[0139]members232 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 lockingmembers232 and varying the tension in thelace23, a user may provide zones of varied tightness along the lace pathway.
• FIGS. 16 and 17 show one embodiment of a locking[0140]member232 that is coupled to theboot flap32. The lockingmember232 comprises anactuator234 having anelongate arm235 that extends outwardly from anenlarged cam portion236 having a roundedbottom edge240. Thelace23 is interposed between therounded edge240 of thecam portion236 and theflap32. Theenlarged cam portion236 of theactuator234 is rotatably mounted to theflap32, such as through arotatable pin connector242. As shown in FIG. 16, theactuator234 may be moved to first or engaged position wherein therounded edge240 engages thelace23 and applies a tightening force to secure the lace against theflap32. The lockingmember232 thereby prevents movement of thelace23 relative to theshoe flap32.
• With reference to FIG. 17, the[0141]actuator234 may also be moved to a second, non-engaged orientation wherein therounded edge240 of thecam portion236 is removed from engagement with thelace23 to thereby allow movement of thelace23 relative to theflap32.
• FIG. 18 shows another embodiment of a[0142]lace locking member312 comprised of a multi-piece structure including afirst member314 and asecond member322 coupled thereto. As best shown in the cross-sectional view of FIG. 19, the first member has a pair ofshafts316 extending therethrough. A pair of bore holes315 (FIG. 18) in thefirst member314 communicate with theshafts316. An elongatetubular compression clamp320 is located within each of theshafts316. Theshafts316 and the compression clamps320 are sized to receive thelace23 therethrough, as shown in FIG. 19.
• The[0143]second member322 is movably coupled to thefirst member314. Thesecond member322 includes a pair ofpegs324 that extend into the bore holes315 in thefirst member314. Ascrew326 is coupled to thefirst member314 and thesecond member322. Thesecond member322 may be incrementally moved toward thefirst member314 by turning thescrew326. As thescrew326 is turned, thepegs324 incrementally slide into thelace shafts316 and pinch or compress the compression clamps320. When the lace is disposed within the compression clamps320, the compression coupling between thepegs324 and the compression clamps320 is transferred to thelace23 to inhibit thelace23 from moving. The user may adjust thescrew326 to vary the level of compression that thepegs324 apply to thelace23.
• The compression clamps[0144]320 are preferably made of a soft, deformable material that will deform when thepegs324 apply pressure thereto. Advantageously, the soft compression clamps320 exert sufficient compression to thelace23 with reduced risk of deformation to thelace23. The lockingmember312 may be disposed at various locations along the lace pathway to allow the user to create zones of varying tightness, as described previously.
• As mentioned, the locking[0145]members232 may be located at any of a wide variety of locations along the lace pathway to allow the user to fix the position of thelace23 at any of these locations. Other mechanical or structural designs may be used to lock the lace relative to the tightening mechanism. For example, the entryways of the guide members may be fitted with a collect to engage thelace23.
• FIG. 20 is a front view of the instep portion of the[0146]boot20. In the embodiment shown in FIG. 20, thetubular guide members50 and52 are mounted directly within theflaps32,34, such as within or between single or multiple layers of material. Preferably, thetips150 of each of theguide member50,52 protrude outwardly from aninner edge152 of each of theflaps32,34. As best shown in FIG. 21, a set ofstitches154 surrounds eachguide member50 and52. Thestitches154 are preferably positioned immediately adjacent theguide members50,52 to create agap156 therebetween. For ease of illustration, thegap156 is shown having a relatively large size with respect to the diameter of theguide members50,52. However, the distance between eachguide member50,52 and therespective stitches154 is preferably small.
• Preferably, each set of[0147]stitches154 forms a pattern that closely matches the shape of the respective guide members so that theguide members50,52 fit snug within theflaps32,34. Thestitches154 thereby inhibit deformation of theguide members50,52, particularly the internal radius thereof, when the lace is tightened. Advantageously, thestitches154 also function as anchors that inhibit theguide members50,52 from moving or shifting relative to theflaps32,34 during tightening of the lace.
• The[0148]gap156 may be partially or entirely filled with a material, such as glue, that is configured to stabilize the position of theguide members50,52 relative to theflaps32,34. The material is selected to further inhibit theguide members50,52 from moving within thegap156. As shown in FIG. 22, the guide members may also be equipped with anchoring members, such astabs160 of various shape, that are disposed at various locations thereon and that are configured to further inhibit theguide members50,52 from moving or deforming relative to theflap32. The anchoring members may also comprise notches or grooves on theguide members50,52 that generate friction when theguide members50,52 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[0149]guide tubes50 or52 may also be limited through the use of any of a variety of guide tube stops such as that illustrated in FIG. 22A. The guide tube stop includes a tubular body having anopening51 which provides access to acentral lumen53 extending therethrough. The stop may also be provided with one ormore fastening tabs160, for sewing or gluing to the shoe, as has been discussed.Tabs160, once stitched or otherwise secured into place, resist axial movement of the device along its longitudinal pathway.
• The[0150]central lumen53 extends to a radially outwardly extendingstep57, producing achamber55 having a greater inside diameter than thelumen53 at theopening51.Chamber55 is dimensioned to slideably receive an end of aguide tube50 or52 therein. Theannular step57 inhibits movement of the guide tube in the direction ofopening51. The stop may be manufactured in accordance with any of a variety of techniques, such as injection molding or machining from suitable materials including plastics and metal. In one embodiment, theguide tube52 comprises ______, and the stop comprises ______. The end of the guide tube may be secured withinchamber55 using any of a variety of adhesives, solvent bonding, thermal bonding, interference fit or other techniques known in the art, or simply held in place by tension on the lace. In one embodiment, thetube50 is bonded within the stop using ______.
• In any of the embodiments discussed elsewhere herein, the exit point on the lace guide or other structure may be made from a harder, more durable material than the rest of the lace guide. In the case of a tubular lace guide, the lace guide is often preferably flexible so that it can flex with the boot. Most of the wear takes place at the exit point of the cable, where reinforcement may be desirable. In addition, the tube stop can be made completely of metal or other high durometer material while the corresponding tubular lace guides are more flexible. This may be accomplished in a variety of ways, such as using metal or high durometer plastic ring inserts or attachments or coatings at the lace exit point as will be apparent to those of skill in the art in view of the disclosure herein.[0151]
• By providing a stop on each end of a[0152]guide tube50 or52, movement of theguide tube50 or52 along its longitudinal axis under normal use conditions can be prevented.
• In any of the foregoing embodiments, the external opening to the lace guide is subject to wear by the cable advancing in and out as the product is used. The durability of the lace guide may be improved by including an annular ring of a harder durometer material at the lace guide opening. Alternatively, a metal ring can be attached at each lace guide opening, using any of a variety of attachment techniques known in the art, including insert molding, adhesive bonding, threaded engagement and others known in the art. As a further alternative, a portion of the lumen extending through the lace guide may be lined using a metal tube such as an appropriately sized hypodermic needle tubing, taking into account the diameter of the lace. The tubing can extend slightly beyond the opening to the central lumen in the plastic-molded or formed part.[0153]
• With reference to FIGS. 23 and 24, an[0154]alternative guide member250 comprises a thin, single-piece structure having aninternal lumen252 for passage of thelace23 therethrough. Theguide member250 includes amain portion254 that defines a substantially straightinner edge256 of the guide member. Aflange portion260 extends peripherally around one side of themain portion254. As best shown in FIG. 22, theflange portion260 comprises a region of reduced thickness with respect to themain portion254. Anelongate slot265 comprised of a second region of reduced thickness is located on theupper surface266aof theguide member250.
• A pair of lace exit holes[0155]262 extend through a side surface of thelace guide member250 and communicate with thelumen252. The lace exit holes262 may have an oblong shape to allow thelace23 to exit therefrom at a variety of exit angles.
• With reference to FIGS. 23 and 24, a series of upper and[0156]lower channels264a,264b, respectively, extend through upper andlower surfaces266a,266b, respectively, of thelace guide member250. The channels264 are arranged to extend along the pathway of thelumen252 and communicate therewith. The location of each of theupper channels264apreferably successively alternates with the location of each of thelower channels264balong the lumen pathway so that theupper channels264aare offset with respect to thelower channels264b.
• With respect to FIGS. 25 and 26, the[0157]lace guide member250 is mounted to theflaps32,34 by inserting theflange region260 directly within theflaps32,34, such as within or between single or multiple layers255 (FIG. 26) of material. Thelayers255 may be filled with afiller material257 to maintain a constant thickness in theflaps32,34.
• The[0158]lace guide member250 may be secured to theflaps32,34, for example, by stitching a thread through theflap32,34 and through thelace guide member250 to form astitch pattern251. The thread is preferably stitched through the reduced thickness regions of theflange portion260 and theelongate slot265. Preferably, theflaps32,34 are cut so that themain portion254 of theguide member250 is exposed on theflap32,34 when thelace guide member250 is mounted thereon.
• With respect to FIG. 26, the[0159]upper surface266aof the main portion of theguide member250 is preferably maintained flush with the upper surface of theflaps32,34 to maintain a smooth and continuous appearance and to eliminate discontinuities on theflaps32,34. Advantageously, because theflange region260 has a reduced thickness, thelace guide member250 is configured to provide very little increase in the thickness of theflaps32,34, and preferably no increase in the thickness of the flaps. Thelace guide member250 therefore does not create any lumps in theflaps32,34 when theguide member250 is mounted therein.
• As mentioned, a series of upper and lower offset[0160]channels264a, bextend through thelace guide member250 and communicate with thelumen252. The offset arrangement of the channels advantageously facilitates manufacturing of theguide members250 as a single structure, such as by using shut-offs in an injection mold process.
• 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.[0161]
• FIG. 27 is a side view of an[0162]alternative tightening mechanism270. Thetightening mechanism270 includes anouter housing272 having a control mechanism, such as arotatable knob274, mechanically coupled thereto. Therotatable knob274 is slideably movable along an axis A between two positions with respect to theouter housing272. In a first, or engaged, position, theknob274 is mechanically engaged with an internal gear mechanism located within theouter housing272, as described more fully below. 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. Abottom plate273 is disposed at a bottom end of theouter housing272. A set of mountingarms275 extends radially outwardly from thebottom plate273, to removably engage a mounting structure discussed below.
• FIG. 28 is a cross-sectional view of the[0163]tightening mechanism270. A gear mechanism276 (shown schematically) is disposed within a lower region of theouter housing272 and is mechanically coupled to therotatable knob274 via ashaft280. Theshaft280 is mechanically coupled to the knob, such as through a spline interface.
• A lace wind-up[0164]spool282 is interposed between thegear mechanism276 and thecontrol knob274. Theshaft280 is journaled through thespool282. Thespool282 is mechanically coupled to thegear mechanism276. Thespool282 includes a pair ofannular grooves284a, bthat are sized to receive thewound lace23. Thespool282 rotates about the axis of theshaft280 in response to rotation of thecontrol knob274.
• The[0165]control knob274 is configured to be incrementally rotated in a forward rotational direction, i.e., in a rotational direction that causes thelace23 to wind around thespool282. Toward this end, thecontrol knob274 preferably includes a series of integrally-mountedpawls277 that engage corresponding series of ratchets on theouter housing272. See FIGS.31-32. Thepawls277 are preferably permanently engaged with theratchets279 when thecontrol knob274 is in the coupled or uncoupled position. The ratchet/pawl engagement prevents theknob274 and thespool282 from being rotated in a backwards direction (i.e., in a rotational direction opposite the rotational direction that winds thelace23 around the spool282) when theknob274 is in the coupled position. This configuration prevents the user from inadvertently winding thecontrol knob274 backwards, which could cause thelace23 to kink or tangle in thespool282. The risk of tangling is especially high where a large length oflace23 is wound around the spool, such as in the present case, where from about six inches up to about 2 feet of cable length (one half on each end) is wound around thespool282.
• Referring to FIG. 30, the[0166]knob274 is illustrated to show moveability between two positions, a coupled position (left side of drawing) and an uncoupled position (right side of drawing). Thepawls277 on theknob274 are slideably engaged with the ratchets on the case so they are engaged in either position so the knob can never be rotated backwards. In the engaged position, the spline teeth on the knob are coupled to the spline teeth on theshaft280 which effectively couples the ratchet/pawl system to the gear train andspool282 so thelace23 cannot unwind. The only way to unwind thelace23 from thespool282 is to pull theknob274 out into the uncoupled position which uncouples the splines allowing the spool to spin freely in either direction. The lace is then pulled off the spool manually. A deflectable indent washer mounted onto the shaft presses against theknob274 and falls into one of two indents in the knob. This holds the knob by friction in either the coupled or uncoupled position. Although in this embodiment, the permanently engaged ratchet/pawl assembly is uncoupled from the spool by pulling out the knob, this uncoupling could be accomplished in several different ways by someone skilled in the art.
• With reference to FIG. 28, a pair of lace entry holes[0167]296a, bare disposed on the side of theouter housing272 of thetightening mechanism270. The lace entry holes296a, bcommunicate with theannular grooves284a, b, respectively, in thespool282. A pair of lace retention holes300a, bare disposed in the spool within thegrooves284a, b. respectively. Each of the lace retention holes300a, bcomprises a cylindrical bore that extends radially into thespool282. The lace retention holes300a, bare sized to receive the end oflace23 therein. A pair ofcounterbores302 extend downwardly through thespool282 and communicate with the lace retention holes300a, b. An attachment device, such as set screw304, is disposed within each of thecounterbores302. The set screws304 may be rotated to incrementally project bottom ends thereof into the lace retention holes300a, b.
• The[0168]spool282 may be rotated so that each of the lace retention holes300a, baligns with a correspondinglace entry hole296a, b, respectively, as shown in FIG. 28. Toward this end, analignment hole301 is located in thespool282 and acorresponding alignment hole303 is located in theouter housing272. The twoalignment holes301,303 may be aligned through rotation of thespool282. Preferably, when theholes301,303 are aligned, the lace retention holes300 are also aligned with the lace entry holes296. The user may thereby quickly and easily align the lace retention holes300 with the lace entry holes296 by aligning the alignment holes301,303 and then inserting a pin therein to fix the position of thespool282 with respect to theouter housing272.
• The[0169]lace23 is installed onto thetightening mechanism270 by first rotating thespool282 so that the lace retention holes300a, balign with the corresponding lace entry holes296a, b, as described above. The ends of thelace23 are then each inserted into separate lace entry holes296a, buntil the lace ends abut an inner surface of the lace retention holes300a, b. The set screws304 are then individually rotated so that the bottom ends of the set screws304 engaged or pinch the lace ends to thereby secures thelace23 within the retention holes300a, b. Thecontrol knob274 may be rotated in the forward direction to wind thelace23 around thespool282. Thelace23 may be removed from thespool282 by loosening the set screws304 to disengage the set screws304 from the lace end and then pulling thelace23 from thespool282.
• As mentioned, the lace entry holes[0170]296a, bshould be aligned with the corresponding lace retention holes300a, bwhen inserting the lace ends into the entry holes296a, b. As shown in FIG. 29, the lace end will not enter the retention hole300 but will rather abut the inner surface of thespool282 if the holes296,300 are not correctly aligned. The user will then not be able to engage the set screw with thelace23. The ends of thelace23 preferably each include a marker orindicator310 to assist the user in installing thelace23 into thelace retention hole300a, b. Theindicator310 is located a preselected distance from the end of thelace23, which is preferably substantially equal to the distance D between the inner surface of the lace retention hole300 and the location of lace entry hole296.
• If the lace entry hole[0171]296 and the lace retention hole300 are misaligned during installation of thelace23, theindicator310 will be clearly visible to the user, as shown in FIG. 29. However, if thelace23 is correctly positioned within the lace retention hole300, theindicator310 will be flush with the entry point of the lace entry hole296. Advantageously, the user can confirm the that lace is correctly positioned within the lace retention hole300 when the indicator on the lace is aligned with the entry point of the lace entry hole296.
• The[0172]tightening mechanism270 may be removably mounted to the front, back, top or sides of the boot. In the illustrated embodiment, the tightening mechanism is mounted to thetongue36 of theboot20 between theflaps32,34. In one embodiment, a bayonet-type mounting system is used to mount thetightening mechanism270 to thetongue36. Thetongue36 may include a sheet of flexible material, such as plastic, mounted therein or thereover. The material may include die-cut hole that mates with a corresponding bayonet structure on the bottom plate273 (FIG. 27) of thetightening mechanism270. The die cut hole may be, for example, key-shaped so that the bayonet structure may be inserted therein and twisted to lock the bayonet structure within the hole.
• The base for one bayonet mounting system is illustrated in FIG. 27A. The mounting[0173]ring330 comprises anattachment structure332 for attachment to the boot. In the illustrated embodiment, theattachment structure332, comprises a radially outwardly extending flange suitable for attachment to the tongue or other portion of the boot by sewing, adhesive bonding, grommets or other fastening techniques known in the art. The mountingring330 is provided with acentral aperture334 for removably receiving the base of a reel. One or more axially extendingrecesses336 are provided, to slideably receive one or more mountingarms275 therethrough. When the base of the reel has been advanced into theaperture334 such that the mountingtab275 has advanced through the length of thegroove336, the base of the reel may be rotated to offset the mountingtab275 from thegroove336 thereby locking the reel in place. In the illustrated embodiment, fourgrooves336 are illustrated to accommodate four mountingtabs275. Preferably, two or more corresponding336 and mountingtabs275 will be utilized to provide secure retention.
• A[0174]releasable lock338 may also be provided. Thelock338 preferably resists rotation of the base such that the base can become separated from the mountingring330. In the illustrated embodiment, thelock338 comprises aflexible arm340 having a radially inwardly extendingengagement surface342 such as on a tooth. Once the base has been advanced through theaperture334 and rotated to provide an interference fit, theengagement surface342 advances under the spring bias supplied byarm340 into a corresponding recess on the base. By rounding the edges of the tooth, and dimensioning the recess, the engagement provided bylock338 can be sufficient to resist detachment under normal use conditions. However, when removal of the spool is desired, the spool may be forced to rotate by overcoming the resistance provided bylock338 as will be appreciated by those of skill in the art in view of the disclosure herein. Advantageously, such a design allows the tightening mechanism to be quickly and easily mounted and dismounted from theboot20 without the use of tools. Alternatively, it may be desirable to prevent removal of the reel from the bayonet without the use of a special tool. This latter construction will minimize accidental removal of the reel. Any of a variety of locking structures, which may be released using a special screw driver or other tool may be readily incorporated into the present design. Alternatively, a small aperture in the reel may be provided, into which a wire such as a paper clip size pin is inserted to advance a release mechanism to release the reel to bayonet.
• Certain functional advantages of embodiments of the present invention can be further illustrated in connection with FIGS. 30 through 32. In particular, 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 prevent 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.[0175]
• Thus, referring to FIG. 30, a[0176]knob274 is shown split down the middle such that the left half of the figure illustrates the knob in the coupled position and the right half of the figure illustrates the knob in the uncoupled position. In the coupled position, rotation of the knob in the forward direction winds lace around the reel. Unwinding of the lace is prevented, despite the tension in the tightened system. In the uncoupled position, traction on the lace causes the reel to unwind. However, the reel is not windable in the reverse direction by rotating the knob.
• One manner of accomplishing the foregoing is to provide a[0177]spline314 on the shaft, for engagement with aspline312 on the knob when the knob is in the coupled position. As illustrated, when theknob274 is in the uncoupled position, thespline314 on the shaft is disengaged from thespline312 on the knob, thereby enabling the reel to be wound in a reverse direction in response to traction on the lace. A radiallymoveable indent washer316 is slideably moveable between anuncoupled recess318 and a coupledrecess320. Any of a wide variety of structures can be utilized to accomplish this result as will be apparent to those of skill in the art in view of the disclosure herein. Theindent washer316 both inhibits accidental movement of theknob274 from the coupled position to the uncoupled position, and also provides tactile feedback to the user so that the knob will snap into the coupled position or the uncoupled position as desired. A stabilizingwasher322 or other spacer may also be provided, to prevent wobbling of theknob274.
• Detailed views shown in FIG. 31 and[0178]32 illustrate, for example, a plurality of integrally moldedpawls277 on theknob274. Thepawls277 are sufficiently axially elongated that they engage the housing in both the coupled position and the uncoupled position to prevent reverse rotation of theknob274. The correspondingratchet teeth279 on the case are illustrated in FIG. 32.
• 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.[0179]
• 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 bottomed 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 to long, the wearer may accidentally wind in the lace cable until it jams tightly against the reel housing and cannot be pulled back out.[0180]
• Although the present invention has been described in terms of certain preferred embodiments, other embodiments can be readily devised by one with skill in the art in view of the foregoing, which will also use the basic concepts of the present invention. Accordingly, the scope of the present invention is to be defined by reference to the following claims.[0181]

Claims (21)

What is claimed is:

1. A footwear lacing system, comprising:

a footwear member including first and second opposing sides configured to fit around a foot;

a plurality of opposing cable guide members positioned on the opposing sides;

a single strand nickel-titanium alloy cable guided by the guide members, the cable having a first end and a second end, the cable rotationally linked to a spool; and

a tightening mechanism attached to the footwear member and coupled to the spool, the tightening mechanism including a control for winding the cable around the spool to place tension on the cable thereby pulling the opposing sides towards each other.

2. A footwear lacing system as inclaim 1, wherein the first and second ends are removably connected to the spool.

3. A footwear lacing system as inclaim 1, wherein the first and second ends are fixed to the spool.

4. A footwear lacing system as inclaim 1, wherein the cable is connected to the spool at a point spaced apart from the ends of the cable.

5. A footwear lacing system as inclaim 1, wherein the cable extends through a bore through the spool.

6. A footwear lacing system as inclaim 1, wherein the cable is removably connected to the spool such that the cable may be removed from the footwear lacing system without removing the spool.

7. A footwear lacing system as inclaim 1, wherein the cable has a diameter within the range of from about 0.020″ to about 0.040″.

8. A footwear lacing system as inclaim 7, wherein the cable has a diameter within the range of from about 0.025″ to about 0.035″.

9. A footwear lacing system as inclaim 8, wherein the cable comprises rounded ends.

10. A footwear lacing system as inclaim 1, wherein the cable is slideably positioned around the guide members to provide a dynamic fit in response to movement of the foot within the footwear.

11. A footwear lacing system as inclaim 10, further comprising at least one expansion limiting band thereon, which resides in an expansion limiting plane.

12. A footwear lacing system as inclaim 11, wherein the expansion limiting band is positioned on the footwear such that it surrounds the wearer's ankle.

13. A footwear lacing system as inclaim 12, wherein the expansion limiting plane extends substantially horizontally through the footwear.

14. A footwear lacing system as inclaim 1, wherein the tightening mechanism comprises a rotatable reel for receiving the lace.

15. A footwear lacing system as inclaim 14, further comprising a rotatable knob, selectively engageable with the reel.

16. A footwear lacing system as inclaim 15, wherein the knob is rotatable only in a first, lace tightening direction.

17. A footwear lacing system as inclaim 15, wherein the knob is moveable between an engaged position and a disengaged position, and the reel is rotationally locked to the knob when the knob is in the engaged position.

18. A footwear lacing system as inclaim 17, wherein the knob has an axis of rotation and the knob is moveable between the engaged position and the disengaged position by moving the knob along the axis of rotation.

19. A method of balancing tension along the length of a lacing zone in a boot, comprising the steps of:

providing a boot having first and second opposed sets of guide members, and a lace extending back and forth between the first and second opposed guide members, the guide members each defining a pathway through which the lace slides, and a rotatable tightening mechanism on the boot for retracting lace thereby advancing the first and second set of opposed guide members towards each other to tighten the boot;

rotating the tightening mechanism to retract lace thereby advancing the first and second opposing sets of guide members towards each other to tighten the boot;

permitting the lace to slide through the guide members, to distribute the tightening force along the length of the guide members and to equilibrate tightening force along the length of the lacing zone on the boot; and

limiting expansion in at least one plane through the lacing zone by fastening an expansion limiting strap in the plane.

20. 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 a least a second lace guide attached to the medial side of the upper;

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;

a tightening reel on the footwear, for retracting the lace, thereby advancing the first lace guide towards the second lace guide to tighten the footwear; and

a knob moveable between a coupled position and an uncoupled position;

wherein the knob is rotatable in a forward direction and the reel is rotationally coupled to the knob when the knob is in the coupled position, and the reel is rotatable in a reverse direction when the knob is in the uncoupled position.

21. A closure system for footwear as in claim20, wherein each of the first and second lace guides comprises a tube.

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