Reel based lacing system

A reel based lacing system is disclosed. The reel can be configured to allow the incremental tightening of a lace about a spool by rotation of a knob in the tightening direction. In some embodiments, the system can include a substantially inflexible pawl beam configured to resist rotation of the knob in the loosening direction and a pawl spring configured to bias the pawl against the housing and to allow the pawl to be displaced away from the housing when the knob is rotated in the tightening direction.

BACKGROUND OF THE INVENTION

1. Field of the Invention

Embodiment disclosed herein relate to lacing or closure systems and their related components used alone or in combination in any variety of articles including footwear, closeable bags, protective gear, etc.

2. Description of the Related Art

There exist a number of mechanisms and methods for tightening articles such as footwear. Nevertheless, there remains a need for improved devices and methods.

SUMMARY OF THE INVENTION

In some embodiments, a reel for use in a lacing system is disclosed. The reel can include a housing having a plurality of housing teeth. The reel can include a spool supported by the housing, and the spool can be rotatable with respect to the housing. The spool can include a channel formed therein, and the channel can be configured to collect a lace therein to tighten the lacing system as the spool is rotated in a tightening direction. The channel can release lace therefrom to loosen the lacing system as the spool is rotated in a loosening direction. The reel can include a knob supported by the housing, and the knob can be rotatable with respect to the housing. The knob can be coupled to the spool such that rotation of the knob causes the spool to also rotate. The knob can include one or more pawls, and at least one of the one or more pawls can include a pawl beam and a pawl spring. The pawl beam can be movable between a first position and a second position, and the pawl spring can be configured to bias the pawl beam toward the first position. The pawl beam can include one or more pawl teeth configured to engage the housing teeth when the pawl beam is in the first position to prevent the knob from rotating in the loosening direction when a loosening force is applied to the knob without transferring a substantial portion of the loosening force to the pawl spring. In some embodiments, the pawl beam and the pawl spring can be integrally formed (e.g., integrally molded). In some embodiments, the one or more pawl teeth can be displaced away from the housing teeth to the second position when the knob is twisted in the tightening direction to allow the knob and spool to rotate in the tightening direction.

In some embodiments, the housing teeth can extend in a radial direction, and the pawl beam can be radially movable between the first position and the second position, and the knob can be axially movable between an engaged position and a disengaged position. When the knob is in the disengaged position, the spool can be permitted to rotate in the loosening direction. The one or more pawls can be configured to engage the housing teeth such that, when the loosening force is applied to the knob, the knob is prevented from rotating in the loosening direction without applying substantial force to the knob in the axial direction.

In some embodiments, a pawl is disclosed, and the pawl can include at least two pawl teeth configured to simultaneously engage at least two corresponding housing teeth such that a loosening force is distributed across multiple teeth to prevent rotation in the loosening direction. In some embodiments, the pawl beam can be configured to be urged toward the housing teeth when a loosening force is applied to the knob. A loosening force can be applied to the knob by a user twisting the knob in the loosening direction or by tension on the lace coupled to the spool. The pawl beam can be configured to rotate radially about a pivot axis, and one or more of the pawl teeth can engage the housing teeth at a location that is radially outward from a tangent line extending from the pivot axis. The pawl teeth can have a surface configured to press against a surface of the housing teeth when a loosening force is applied to the knob such that the pawl beam is urged towards the housing teeth when a loosening force is applied. The pawl beam can be prevented from moving to the second position unless the knob is rotated in the tightening direction to disengage the surface of the at least one pawl tooth from the surface of the housing tooth. A side of the pawl beam can be configured to abut against one or more tips of housing teeth that are not engaged by the one or more pawl teeth when a loosening force is applied to the knob and the pawl beam is urged toward the housing teeth to provide added support.

In some embodiments, a method of making a reel for use in a lacing system is disclosed. The method can include providing a housing, and the housing can include a plurality of housing teeth. The method can include placing a spool within the housing such that the spool is rotatable with respect to the housing. The spool can include a channel formed therein, and the channel can be configured to collect a lace therein to tighten the lacing system as the spool is rotated in a tightening direction. The channel can be configured to release lace therefrom to loosen the lacing system as the spool is rotated in a loosening direction. The method can include attaching a knob to the housing such that the knob is rotatable with respect to the housing. The knob can be coupled to the spool so that rotation of the knob causes the spool to also rotate. The knob can include one or more pawls, and at least one of the one or more pawls can include a pawl beam and a pawl spring. The pawl beam can be movable between a first position and a second position and the pawl spring can be configured to bias the pawl beam toward the first position. The pawl beam can include one or more pawl teeth configured to engage the housing teeth when the pawl beam is in the first position to prevent the knob from rotating in the a loosening direction when a loosening force is applied to twist the knob in the loosening direction without transferring a substantial portion of the loosening force to the pawl spring. The one or more pawl teeth can be displaced away from the housing teeth to the second position when the knob is twisted in the tightening direction to allow the knob and spool to rotate in the tightening direction. In some embodiments, the pawl beam and the pawl spring can be integrally formed.

In some embodiments, a pawl for use with a reel in a lacing system is disclosed. The pawl can include a pawl beam having one or more pawl teeth configured to interface with housing teeth on a housing of the reel. The pawl beam can be movable between a first position and a second position. The pawl can include a pawl spring configured to bias the pawl beam toward the first position. The one or more pawl teeth can engage the housing teeth when the pawl beam is in the first position to prevent the pawl from moving in a loosening direction when a loosening force is applied to pawl without transferring a substantial portion of the loosening force to the pawl spring. The one or more pawl teeth can disengage from the housing teeth when the pawl beam is in the second position to allow the pawls to move in a tightening direction. In some embodiments, the pawl beam and the pawl spring can be integrally formed.

In some embodiments, a reel for use in a lacing system is disclosed. The reel can include a housing comprising a plurality of housing teeth, and a spool supported by the housing such that the spool is rotatable with respect to the housing. The spool can include a channel formed therein, and the channel can be configured to collect a lace therein to tighten the lacing system as the spool is rotated in a tightening direction and to release lace therefrom to loosen the lacing system as the spool is rotated in a loosening direction. The reel can include a knob supported by the housing such that the knob is rotatable with respect to the housing. The knob can be coupled to the spool such that rotation of the knob causes the spool to also rotate. The knob can include one or more pawls configured to interface with the housing teeth, and at least one of the one or more pawls can include a flexible pawl arm attached to the knob at a first end and having one or more pawl teeth formed on a second end. The pawl arm can be configured to flex in a first direction as the knob is rotated in the tightening direction such that the one or more pawl teeth are displaced away from the housing teeth to allow the knob to rotate in the tightening direction. The pawl arm can be configured such that when a loosening force is applied to twist the knob in the loosening direction, the one or more pawl teeth engage the corresponding housing teeth to prevent the knob from rotating in the loosening direction, and the loosening force causes the flexible pawl arm to flex in a second direction toward the housing teeth such that the flexible pawl arm abuts against the housing teeth to prevent the flexible pawl arm from buckling under the loosening force.

In some embodiments, a pawl is disclosed that includes a substantially rigid pawl beam and a flexible pawl spring. The pawl spring can be a flexible arm. In some embodiments, the pawl beam can be movable between a first position and a second position, and the pawl spring can be configured to bias the pawl beam toward the first position. The flexible arm can assume a less flexed position when the pawl beam is in the first position, and the flexible arm can assume a more flexed position when the pawl beam is in the second position. In some embodiments, the flexible arm can be less curved when in the more flexed position than when in the less flexed position. In some embodiments, the flexible arm can extend generally in the same direction as the pawl spring. In some embodiments, the pawl beam and the pawl spring can be integrally formed.

In some embodiments, a knob is disclosed that can be used with a reel in a lacing system. The knob can include one or more pawls. At least one of the one or more pawls can be coupled to the knob at a pivot axis. The at least one pawl can include a pawl beam configured to rotate about the pivot axis between a first position and a second position, and a pawl spring can bias the pawl beam toward the first position where the pawl beam engages housing teeth on the reel to prevent the knob from rotating in a loosening direction. In some embodiments, the pawl spring can extend from near the pivot axis in generally the same direction as the pawl beam. In some embodiments, the pawl spring can be a flexible arm. In some embodiments, the flexible arm can curve away from the pawl beam. The pawl spring can be integrally formed with the pawl beam.

In some embodiments, a reel for use in a lacing system is disclosed. The reel can include a housing having a plurality of housing teeth. The reel can include a spool supported by the housing, and the spool can be rotatable with respect to the housing. The reel can include a knob supported by the housing, and the knob can be rotatable with respect to the housing. The knob can be coupled to the spool such that rotation of the knob causes the spool to also rotate. The knob can include one or more pawls, and at least one of the one or more pawls can include a substantially rigid pawl beam and a pawl spring. The pawl beam can be movable between a first position and a second position, and the pawl spring can be configured to bias the pawl beam toward the first position. The pawl beam can include one or more pawl teeth configured to engage the housing teeth when the pawl beam is in the first position to prevent the knob from rotating in the loosening direction. In some embodiments, the one or more pawl teeth can be movable away from the housing teeth to the second position when the knob to allow the knob and spool to rotate in the tightening direction. The substantially rigid pawl beam can be configured to withstand the loosening force. The pawl beam and the pawl spring can be integrally formed in some embodiments.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

FIG. 1is a perspective view of a lacing system100used for tightening a sport shoe102. The sport shoe can be a running shoe, a basketball shoe, and ice skating boot, or snow boarding boot, or any other suitable footwear that can be tightened around a wearer's foot. The lacing system100can be used to close or tighten various other articles, such as, for example, a belt, a hat, a glove, snow board bindings, a medical brace, or a bag. The lacing system can include a reel104, a lace106, and one or more lace guides108. In the illustrated embodiment, the reel104can be attached to the tongue110of the shoe. Various other configurations are possible. For example, the reel104can be attached to a side of the sport shoe102, which can be advantageous for shoes in which the shoe sides112a-bare designed to be drawn closely together when tightened leaving only a small portion of the tongue110exposed. The reel104can also be attached to the back of the shoe102, and a portion of the lace106can pass through the shoe102on either side of the wearer's ankle such that the lace106can be engaged with the reel104when back-mounted.

FIG. 2is a perspective view of a lacing system200that can be similar to the lacing system100, or any other lacing system described herein. The lacing system can include a reel204which can be similar to the reel104, or any other reel described herein.FIG. 3is an exploded perspective view of the reel204.FIG. 4is another exploded perspective view of the reel204.

With reference toFIGS. 2 to 4, the reel204can include a base member214, a spool member216, and a knob member218. The base member can include a housing220and a mounting flange222. The housing220can include a plurality of housing teeth224, which can extend radially inwardly. The housing220can include lace holes226a-bthat allow the lace206to enter the housing220.

The spool member216can be disposed within the housing220such that the spool member216is rotatable about an axis228with respect to the housing220. The lace206can be secured to the spool member216such that when the spool member216rotates in a tightening direction (shown by arrow A) the lace206is drawn into the housing220and is wound around the channel230formed in the spool member216, and when the spool member216rotates in a loosening direction (shown by arrow B) the lace206unwinds from the channel230of the spool member216and exits the housing220via the lace holes226a-b. The spool member216can also include spool teeth232formed thereon. It will be understood that the embodiments disclosed herein can be modified such that rotation in the direction shown by arrow B will tighten the lacing system and such that rotation in the direction shown by arrow A will loosen the lacing system.

The knob member218can be attached to the housing220such that the knob member218can rotate about the axis228with respect to the housing220. The knob member218can include knob teeth234that can be configured to mate with the spool teeth232to couple the knob member218to the spool member216such that rotation of the knob member218in the tightening direction causes the spool member216to also rotate in the tightening direction. In some embodiments, the rotation of the knob member218in the loosening direction can also cause the spool member216to rotate in the loosening direction. The knob member218can also include one or more pawls236which can be biased radially outwardly so as to mate with the housing teeth224. The pawls236and housing teeth224can be configured so that the housing teeth224can displace the pawls236radially inwardly when the knob member218is rotated in the tightening direction, thereby allowing the knob member218to rotate in the tightening direction. The pawls236and the housing teeth224can also be configured so that they engage one another when force is applied to twist the knob member218in the loosening direction, thereby preventing the knob member218from rotating in the loosening direction.

Thus, the reel204can provide a one-way tightening system configured to allow the user to rotate the knob member218in the tightening direction, which causes the spool member216to rotate in the tightening direction, which in turn causes the lace206to be drawn into the housing220via the lace holes226a-b. As the lace206is drawn into the housing220the lacing system200can tighten, causing the lace guide208to be drawn in the direction toward the reel204(shown by arrow C inFIG. 2). Although the lacing system200is shown with a single lace guide208, any other suitable number of lace guides can be used.

In some embodiments, the knob member218can be axially movable along the axis228between a first or engaged position and a second or disengaged position.FIG. 5is a side view of the reel204showing the knob member218in the disengaged position drawn in normal lines and showing the knob member218in the engaged position outlined in dotted lines. When in the engaged position, the spool teeth232can engage with the knob teeth234to couple the knob member218to the spool member216as described above. Also, when in the engaged position, the pawls236can engage with the housing teeth224to allow the knob member218to rotate in the tightening direction while preventing the knob member218from rotating in the loosening direction, as discussed above.

When in the disengaged position, the knob member218can be positioned axially further away from the base member214by a distance238that is sufficient to cause the knob teeth234to lift away from and disengage the spool teeth232so that the spool member216is decoupled from the knob member218and the spool member216is free to rotate separately from the knob member218. Thus, the lace206can be withdrawn from the housing220as the spool member216rotates in the loosening direction causing the lacing system200to loosen. When in the disengaged position, the pawls236of the knob member218can be lifted away from the housing teeth224such that they disengage and the knob member218is free to rotate in the both the tightening and loosening direction without restriction. In some embodiments, when the knob member218is transitioned to the disengaged position, the knob teeth234disengage from the spool teeth232and the pawls236also disengage from the housing teeth224. In some embodiments, when the knob member218is transitioned to the disengaged position, the knob teeth234disengage from the spool teeth232while the pawls236continue to engage the housing teeth224. In some embodiments, when the knob member218is transitioned to the disengaged position, the knob teeth234continue to engage the spool teeth232but the pawls236disengage from the housing teeth224.

The distance238between the engaged and disengaged positions of the knob member318can be at least about 1 mm and/or no more than about 3 mm, and can be about 2.25 mm in some embodiments, although distances outside these ranges can also be used. In some embodiments, the distance238can be approximately the same, or slightly greater than, the height of the spool teeth232, the height of the knob teeth234, the height of the housing teeth224, and/or the height of the pawls236.

In some embodiments, because the pawls236engage the housing teeth224in a radial direction while the knob member218is movable between the engaged and disengaged positioned in the axial direction, the reel204can be resistant to accidental disengagement. When the knob member is in the engaged position, and a force is applied to attempt to twist the knob member218in the loosening direction, or lace is pulled tightly causing the spool member218to attempt to twist in the loosening direction, the force is applied to the pawls236as they engage the housing teeth224. Because the pawls236are configured to be displaced radially, not axially, substantially none of the force applied to the pawls236is transferred in the axial direction. Therefore, the reel204can resist higher tightening pressure than some reels in which knob pawls engage housing teeth in the axial direction.

FIG. 6is a perspective view of the base member214.FIG. 7is a top view of the base member214.FIG. 8is a bottom view of the base member214.FIG. 9is a cross sectional view of the base member214. The base member214a mounting flange222which can be mounted onto the outside structure of an article of footwear or other article, or the mounting flange222can be mounted underneath an outer structure of the article so that at least a portion of the mounting flange222is hidden from view. The mounting flange222can be secured to the article by stitching, or in any other suitable manner such as using an adhesive, or using rivets, etc. The mounting flange222can be contoured to fit a particular portion of the article (e.g., the back of a shoe), or the mounting flange can be flexible to fit a variety of shapes. The mounting flange222can extend fully or partially around the circumference of the housing220. The mounting flange222can be somewhat resilient to accommodate the flexing of the article during use. In some embodiments, the mounting flange222can be omitted, and the base member214or housing220can be mounted to the article by a screw or rivet or other fastener. For example, a threaded portion of the base member214or housing220can be threaded into a corresponding threaded connector on the article. In some embodiments, the mounting flange222is connected to the article and the reel204is subsequently attached to the flange222.

The housing220can be attached to, or integrally formed with, the mounting flange222and can extend upward therefrom, as illustrated. The housing220can include an outer wall240that surrounds a depression242, which can be substantially circular in shape. A shaft244can extend axially upwardly from the base of the depression242, and the shaft244can be aligned substantially coaxially with the depression242. The shaft244can include a step245or beveled portion where the shaft244meets the base of the depression242. The shaft244can include a bore246in the center thereof which can facilitate the securing of the knob member218to the housing220. The bore246can be threaded or otherwise configured to axially secure a fastener that is inserted therein. The shaft244can form a supporting surface about which the spool member216can rotate.

The outer wall240of the housing220can be substantially cylindrical in shape and can be substantially coaxial with the shaft244. The inner surface of the outer wall240can include a lower portion248, and an upper portion250. The lower portion248can be generally smooth and can include a step251or beveled portion where the outer wall240meets the base of the depression242. The lower portion248can include one or more lace openings252a-bwhich can be in connected to the lace holes226a-bby lace channels254a-bso that the lace206can pass through the housing220and enter the depression242. As can best be seen inFIG. 9, a lower portion of the lace channels254a-bnearest to the lace holes226a-bcan be closed while an upper portion of the lace channels254a-bnearest to the lace openings252a-bcan be open at the top. Also, the lace channels254a-band/or the lace openings252a-bcan be in connected to openings256a-bformed in the base of the housing220. The openings256a-band the open tops of the lace channels254a-bcan provide access to the lace206during use and installation, and can also provide an exit pathway for water or other material that may enter the depression242during use, and can facilitate the molding of the lace channels254a-bwhen the base member214is made of few components (e.g., a single integrated piece).

The housing220can include housing teeth224that extend radially inwardly from the upper portion250of the outer wall240. In the illustrated embodiment, the housing includes 36 housing teeth224, but any other suitable number of housing teeth224can be used. As can best be seen inFIG. 7, each of the housing teeth224can include a first side258and a second side260. The first side258can be shorter than the second side260, and in some embodiments, the first side258can be about half as long as the second side260. In some embodiments, the first side258of the housing teeth224can be at least about 0.5 mm long and/or no more than about 1.0 mm long, and can be about 0.85 mm long, and the second side can be at least about 1.0 mm long and/or no more than about 2.0 mm long, and can be about 1.75 mm long. Other dimensions outside of these specific ranges are also possible. The first side258of the housing teeth224can be angled away from a line that points directly radially inwardly by and angle262that can be at least about 5° and/or at most about 15°, and can be about 10° in some embodiments. The second side260of the housing teeth224can be angled away from a line that points directly radially inwardly by an angle264that can be at least about 45° and/or no more than about 65°, and can be about 55° in some embodiments. Other angles outside these specially identified ranges are also possible. In some embodiments, the transition between housing teeth224and between the first and second sides258,260of the housing teeth224can be curved, but hard edged transitions can also be used. The housing teeth224can be configured to interface with the pawls236as discussed in greater detail below. The housing teeth224can include angled top surfaces266to facilitate the transition of the pawls236from the disengaged to engaged positions as will be described in greater detail below.

The base member214can include one or more guard pieces268that can extend axially upwardly further than the outer wall240of the housing220such that the guard piece268can function to cover a portion of the knob member218when the knob member218is attached to the housing220. In some embodiments, the guard piece268can be omitted. In some embodiments, the reel204can be disposed within a recess of the article such that a portion of the article itself extends to cover a portion of the knob member218. The guard268, or portion of the article functioning as a guard, can protect the knob member218and can reduce the occurrence of accidental disengagement of the knob member218.

FIG. 10Ais a perspective view of the spool member216.FIG. 11is another perspective view of the spool member216.FIG. 12is a side view of the spool member216.FIG. 13A-Bare a cross sectional bottom views of the spool member216with the lace206attached thereto.FIG. 14is a top view of the spool member216disposed within the housing220.

The spool member216can include an upper flange270and a lower flange272with a substantially cylindrical wall274formed therebetween. The outer surface of the wall274, the bottom surface of the upper flange270, and the top surface of the lower flange272can form a channel230for collecting the lace206as it is wound around the spool member216. The inner surface of the wall274can surround a depression276formed in the bottom of the spool member216. A central opening278can extend through the ceiling of the depression. As can best be seen inFIG. 14, when the spool member216is disposed within the depression242of the housing220, the shaft244can pass through the central opening278of the spool member216. The step245or beveled edge at the bottom of the shaft244can be received into the depression276formed in the bottom of the spool member216. The lower flange272can be formed slightly smaller than the upper flange270(as can best be seen inFIG. 12) so that the lower flange272can fit inside the step251or beveled edge at the edge of the depression242, and to facilitate removal and/or installation of the spool member216from/into the housing220with the lace206attached. Thus, in some embodiments, the bottom surface of the lower flange272can sit flush against the base of the depression242. In some embodiments, a portion of the housing220can be configured to contact a portion of the spool member216to maintain the bottom surface of the lower flange272a small distance from the base of the depression to reduce the amount of friction as the spool member216rotates. When the spool member216is fully inserted into the depression242of the housing220, the top surface of the upper flange270can substantially align with the top of the lower portion248of the outer wall240such that the upper flange270does not overlap the housing teeth224.

Spool teeth232can be formed on the top surface of the spool member216. In the illustrated embodiment, 12 spool teeth232are shown, but any other suitable number of spool teeth232can be used. Each of the spool teeth232can include a first side280and a second side282. The first side280can be substantially vertical in some embodiments. In some embodiments, the first side can be angled by at least about 5° and/or by no more than about 15°, and in some embodiments by about 10° from the vertical plane. The second side282can be angled by at least about 35° and/or by no more than about 55°, and in some embodiments by about 45° from the vertical plane. The first side280can be at least about 1.5 mm long and/or no more than about 2.5 mm long, and can be about 2.0 mm long. The second side can be at least about 2.5 mm long and/or no more than about 3.5 mm long, and can be about 3.0 mm long. Dimensions and angles outside the identified ranges can also be used. The spool teeth232can be configured to interface with the knob teeth234as discussed in greater detail herein.

In some embodiments, one or more cutouts281a-bcan be formed in the upper flange270of the spool member216. Also, in some embodiments, the upper flange270and/or the lower flange can be substantially circular in shape, but can have one or more flattened edges283a-d. The cutouts281a-band/or the flattened edges283a-dcan facilitate the removal of the spool member216from the housing220(e.g., when replacing the lace206). A screwdriver or other tool can be inserted between the spool member216and the housing220wall and the spool member216can be pried out of the housing220. Many variations are possible. For example,FIG. 10Bis a perspective view of a spool member216′ which is similar to the spool member216in many respects, except that the upper flange270′ and the lower flange272′ of the spool member216′ do not have flattened edges283a-d. Thus, the upper flange270′ and the lower flange272′ can be substantially circular in shape. In some embodiments, the upper flange270′ can include cutouts281a′ and281b′ which can facilitate the removal of the spool member216′ from the housing220. In some embodiments, the flanges270′ and272′ that do not include flattened edges283a-dcan prevent the lace206from becoming trapped or wedged in the gaps formed between the housing220and the flattened edges283a-d, especially when a relatively thin lace is used.

The depth of the channel230can be at least about 1.5 mm and/or no more than about 2.5 mm, and in some cases can be about 2.0 mm. The channel230can have a width that is at least about 3.0 mm and/or no more than about 4.0 mm, and in some cases can be about 3.5 mm. The outer surface of the wall274can have a diameter of at least about 10 mm and/or no more than about 20 mm, and can be in some cases about 14 mm. Dimensions outside the given ranges are also possible. The lace206can be generally small enough in diameter that the cannel230can hold at least about 300 mm of lace and/or no more than about 600 mm of lace, and in some embodiments about 450 mm of lace, although the spool member216and lace206can be configured to hold amounts of lace outside these given ranges.

The lace or cable can have a diameter of at least about 0.5 mm and/or no more than about 1.5 mm, and in some embodiments the diameter can be about 0.75 mm or 1.0 mm, although diameters outside these ranges can also be used. The lace206can be a highly lubricious cable or fiber having a low modulus of elasticity and a high tensile strength. In some embodiments, the cable can have multiple strands of material woven together. While any suitable lace can be used, some embodiments can utilize a lace formed from extended chain, high modulus polyethylene fibers. One example of a suitable lace material is sold under the trade name SPECTRA™, manufactured by Honeywell of Morris Township, N.J. The extended chain, high modulus polyethylene fibers advantageously have a high strength to weight ratio, are cut resistant, and have very low elasticity. One preferred lace made of this material is tightly woven. The tight weave provides added stiffness to the completed lace. The additional stiffness provided by the weave offers enhanced pushability, such that the lace is easily threaded (e.g., into the reel204). Additionally, in some embodiments, the lace can be formed from a molded monofilament polymer. In some embodiments, the lace can be made from woven steel with or without a polymer or other lubrication coating.

One or more ends of the lace206can be secured to the spool member216. In some embodiments, the lace206can be removably or fixedly attached to the spool member216. In some embodiments, the lace206can be threaded through a hole formed in the spool member216and a knot can be formed in the end of the lace206, or an anchoring member can be attached thereto, to prevent the end from being pulled back through the hole. In some embodiments, the lace206can be tied to a portion of the spool member216. The lace can also be secured to the spool member216by an adhesive any other suitable manner. In some embodiments, the lace206is secured to the spool member216by weaving the lace206through a series of openings that cause the lace206to turn at such angles so as to produce sufficient friction to prevent the lace206from being dislodged from the spool member216. In some embodiments, the lace206wraps over itself so that the lace206tightens on itself when pulled. In some embodiments, only one end of the lace206is secured to the spool member216, with the other end of the lace206being secured to the base member214or to the article being tightened.

The spool member216can include a first set of lace holes284a,286a,288awhich can be configured to secure a first end of the lace206. In some embodiments, a second set of lace holes284b,286b,288bcan be used to secure the second end of the lace206. Lace guides290a-bcan also be formed in the depression276to facilitate the securing of the lace206to the spool member216.

In the embodiment shown inFIG. 13A, a first end of the lace206can pass through the lace hole284ainto the depression276. The lace guide290acan direct the lace206toward the lace hole286a, and in some embodiments, the lace guide290acan be positioned such that the lace206is wedged between the lace guide290aand a portion292aof the wall274between the holes284aand286a. The lace206can exit the depression276through the lace hole286aand then turn an angle of approximately 180° to reenter the depression through the lace hole288a. In some embodiments, the tip of the first end of the lace206can be tucked into the opposing lace guide290bto prevent the tip from moving about within the depression276and interfering with the rotation of the spool member216. In some embodiments, the amount of lace206that passes through the lace holes284a,286a,288acan be configured so that only a small portion of the lace206reenters the depression276through the hole288aso that the tip is not tucked into the opposing lace guide290b. The second end of the lace206can be secured to the spool member216by the lace holes284a,286b,288b, and the lace guide290b, and the portion292bof the wall274in like manner.

Other lace securing configurations are possible. For example, in the embodiment shown inFIG. 13B, the first end of the lace206passes through the lace hole284ato enter the depression276. The lace guide290can direct the lace206toward the lace hole288b, and the lace guide290acan be configured such that the lace206is wedged between the lace guide290aand the portion294aof the wall adjacent to the lace hole284a. The lace206can pass through the lace hole288band then turn an angle of approximately 180° to reenter the depression276through the lace hole286b. The second end of the lace206can be secured to the spool member216by the lace holes284b,288a,286a, and the lace guide290band the portion294bof the wall274in like manner.

FIGS. 13C and 13Dillustrate another manner in which the lace206can be secured to the spool member216. As shown inFIG. 13C, the end of the lace216is threaded through the lace hole284ainto the depression276, then through the lace hole286aout of the depression276, and then through the lace hole288aback into the depression276. The end of the lace206can then be passed through the loop in the lace formed between the lace holes284a,286a, as shown inFIG. 13C. The lace206can then be tightened so that the lace crosses under itself as shown inFIG. 13D. For example, the loose end of the lace206can be held with one hand while pulling the loop formed between the lace holes284aand286ato remove the slack from the loop formed between the lace holes286aand288a. Then the slack in the loop formed between the lace holes284aand286acan be pulled out of the depression276through the lace hole284auntil the lace tightens down on itself. Thus, once tightened, the lace206bears down on itself more tightly when it is pulled, thereby preventing the lace206from disengaging from the spool member216.

The lace can pass over the top of the portion of the loop that is closest to the lace hole288aand then under the portion of the loop that is furthest from the lace hole288a, as shown. Then, when the lace is tightened, the loose end of the lace206can be directed generally toward the base of the depression276, rather than being directed generally out from the depression276as would be the case if the lace were threaded over the top of the portion of the loop furthest from the lace hole288a. By biasing the loose end of the lace toward the base of the depression276, the loose end of the lace can be prevented from interfering with the insertion of the spool member216into the housing220. The lace guide190acan be positioned to keep the loose end of the lace206positioned near the periphery of the depression276so that the loose end of the lace206does not enter the central opening278or otherwise interfere with the spool member216being inserted into the housing220.

FIG. 15is an exploded perspective view of the knob member218.FIG. 16is another exploded perspective view of the knob member218. The knob member can include a knob core296, pawls236, a spring bushing298, a fastener300, a knob spring302, a knob cover304, and a knob grip306.

The knob core296can be generally disc-shaped. The knob core296can include knob teeth234formed on the bottom surface thereof. In the illustrated embodiment 12 knob teeth234are shown, but any other suitable number of knob teeth234can be used. In some embodiments, the same number of knob teeth234and spool teeth232can be used, and the knob teeth234can be shaped similar to, or the same as, the spool teeth232, except that that the knob teeth234are oriented in the opposite direction so that the knob teeth234can engage the spool teeth232. Accordingly, the dimensions described above in connection with the spool teeth232can also apply to the knob teeth234. When the knob member218is rotated in the tightening direction, the first sides308of the knob teeth234can press against the first sides280of the spool teeth232to drive the spool member216in the tightening direction. When a lace206is tightened around the spool member216applying a force to the spool member216to cause it to tend to twist in the loosening direction, the second sides282of the spool teeth232can bear against the second sides310of the knob teeth234so that the force is transferred to the knob member218to cause it to tend to twist in the loosening direction. As will be discussed below, the force can cause the pawls236to engage with the housing teeth224to prevent the knob member218and the spool member216from rotating in the loosening direction, thereby maintaining the lace206in the tightened configuration.

The knob core296can include features to facilitate the securing of the knob cover304thereto. The knob core296can include notches312formed in the top surface thereof near the periphery of the knob core296. Protrusions314can extend radially outwardly from the periphery of the knob core296at locations below the notches312. The knob core296can include a central opening316through the center thereof, which can be configured to accept the spring bushing298. A top portion of the central opening316can be wider than a lower portion of the central opening316forming a step318therein. The knob core296can also include features to facilitate the securing of the knob spring thereto, including, for example, a wide engagement tab320and a narrow engagement tab322.

The knob core296can also include pawl depressions324, configured to accept the corresponding pawls236. The pawl depressions324can be generally shaped similarly to the pawls236, but can be somewhat larger than the pawls236to allow the pawls236to pivot and move within the pawl depressions324during operation, as is described in greater detail elsewhere herein. The pawl depressions324can include pawl openings326formed in a portion of the base and/or side thereof to allow a portion of the pawls (e.g., the pawl teeth) to extend through the knob core296(as can be seen in the assembled knob member218shown inFIG. 4) and interface with the housing teeth224.

FIGS. 17 and 18are perspective views of a pawl236. The pawl236can include a pawl base328, a pawl beam330, and a pawl spring332. The pawl base328can be configured to interface with the knob core296and/or the knob cover304so that the pawl236can pivot about an axis334. A pivot tab336can extend upward from the pawl base328along the axis334. The pivot tab336can be substantially cylindrical in shape and can be coaxial with the axis334. A flange337can extend out from one side of the pawl base328, and the flange337can facilitate the pivoting of the pawl236. As can be seen inFIGS. 17 and 18, in some embodiments, the pawl beam330, the pawl spring332, and other components of the pawl236can be integrally formed (e.g., molded) as a single piece.

The pawl beam330can be formed of a material, thickness, and length such that the pawl beam330is substantially rigid and does not flex as the pawl236is displaced by the housing teeth224when the knob member218is rotated in the tightening direction. One or more pawl teeth338a-bcan be positioned near the end of the pawl beam330opposite the pawl base328. In the embodiment shown, two pawl teeth338a-bare used, but any other suitable number of pawl teeth338a-bcan be used instead. The pawl teeth338a-b, and in some cases the entire pawl beam330, can have an angled or beveled bottom surface339which can facilitate the transition of the knob member218from the disengaged position to the engaged position, as is discussed in greater detail elsewhere herein. The pawl beam330can include a step340formed where the end of the pawl beam330extends lower than the rest of the pawl236. The downward extending portion of the pawl beam can be configured to extend through, or into, the pawl opening326formed in the pawl depression324of the knob core296.

The pawl base328can include an end surface328aconfigured to engage surface324aof pawl depression324(as can be seen inFIG. 19). In some embodiments, as pressure is applied to one or more pawl teeth338, the load can be transferred through pawl beam330to the engagement of end surface328aand surface324a. In some embodiments, as the pawl236pivots radially outwardly about the axis334, the end surface328aof the pawl base328can abut against the surface324aof the pawl depression324, thereby limiting the distance that the pawl326can pivot radially outwardly. For example, the pawl236can be permitted to pivot radially outwardly enough to engage the housing teeth224, but not significantly further. This can relieve pressure off of the pawls236when a loosening force is applied to the knob member218, which can produce a component of force urging the pawls236radially outward, as discussed below. The interface between the surfaces328aand324acan also limit the radial movement of the pawls236when the knob member218is in the disengaged position, thereby keeping the pawls236radially inward enough that the knob member218can be pressed to the engaged position without substantial interference from the pawls236. In some embodiments, pawl236is positioned in pawl depression324and is generally trapped between the knob cover304and the knob core296. As explained below, top tabs384can engage pivot tab336to inhibit axial movement of the pawl236. Similarly, beam tabs385extending downward from knob cover304can engage the upper surface of the pawl beam330to inhibit axial movement thereof.

The pawl spring332can be a cantilever or arch spring as shown in the illustrated embodiment, but any other suitable type of spring can be used. The pawl spring332can extend out from the pawl base328in the same general direction as the pawl beam330. The pawl spring332can be curved away from the pawl beam330. A generally cylindrically shaped end piece342can be formed at the end of the pawl spring. The pawl spring332can be made of a material, thickness, and length such that the pawl spring332is resiliently flexible so that it flexes as the pawl236is displaced by the housing teeth224when the knob member218is rotated in the tightening direction. The pawl spring332is shown in the relaxed position inFIGS. 17 and 18. In some embodiments, the pawl beam330and the pawl spring332are independently formed and then coupled to form the pawl236. Thus, pawl beam330and pawl spring332need not be formed of the same material. For example, a metal pawl beam330may be advantageous because of its relatively high strength to thickness ratio while it may be advantageous to use a plastic pawl spring332. In some embodiments, the same material may be used in each, even when the beam pawl beam330and the pawl spring332are separately formed. In the illustrated embodiment ofFIGS. 17-18, the pawl spring332and the pawl beam330can be integrally formed of the same material as a single piece, thereby simplifying the manufacturing and assembly cost and complexity. In some embodiments, different springs may be used than that shown in the illustrated embodiments. For example, a metal or plastic leaf spring or a wire coiled spring may be used in some applications.

Because the pawl beam330and pawl spring332are separate portions, the pawl spring332can be altered to be more easily flexible (e.g., by making the pawl spring332thinner) without reducing the amount of force the pawl beam330is able to withstand as the knob member218is twisted in the loosening direction. Likewise, the pawl beam330can be altered so that it can withstand greater force applied to the knob218in the loosening direction (e.g., by making the pawl beam330thicker) without making the pawl spring332less flexible. Thus, the pawl236can be tuned to a desired level of flexibility and strength. For example, a pawl236can be configured to withstand large amounts of force when the knob member218is twisted in the loosening direction while also being easily radially displaceable when the knob member218is rotated in the tightening direction. In some embodiments, the force applied to the pawl236when the knob member218is twisted in the loosening direction is born by the pawl beam330and substantially none of the force is born by the pawl spring332. This configuration can be advantageous over embodiments in which a pawl includes a load bearing beam that also flexes to displace the pawl (e.g., during tightening), because the load bearing capability of the flexible pawl is reduced as the pawl is made more flexible, and the flexibility of the pawl is reduced as the beam is made to withstand higher forces. Thus, when using the flexible beam pawl, a sufficient amount of loosening force can cause the pawl beam to buckle, thereby compromising the lacing system. However, when using the pawls236, the pawl beam330can be configured to be substantially rigid even when a relatively large loosening force is applied, and the pawl spring332can be configured to allow the pawl beam330to pivot easily when a tightening force is applied.

FIG. 19is a top view showing the pawls236positioned inside of the pawl depressions324of the knob core296. Although the housing220is not shown inFIG. 19, the pawls236are shown in the position where the pawl teeth338a-bare engaged with the housing teeth224.FIG. 20is a top view showing the base member214and the pawls236in the same position as inFIG. 19with the pawl teeth338a-bengaged with the housing teeth224.FIG. 21is a top view of the base member214and the pawls236in a displaced configuration as the knob member218is rotated in the tightening direction. The elements of the knob member218, other than the pawls236, and the spool member216are omitted from the view shown inFIGS. 20 and 21for simplicity.

In some embodiments, the pawl springs332can be partially flexed to a position that is less curved than the relaxed position when inserted into the pawl depressions324. The flexed pawl springs332can cause the pawls236to tend to pivot so that the pawl beams330are biased radially outwardly and so that the pawl teeth338a-bbear radially outwardly against the housing teeth224. When the knob member218is twisted in the loosening direction (shown by arrow B) the first sides344a-bof the pawl teeth338a-bcan bear against the first sides258of the housing teeth224to prevent the knob member218from rotating in the loosening direction. In some embodiments, the pawl depressions324can be configured to receive the pawls236without the pawl springs332needing to be partially flexed. Thus, in some embodiments, the pawl springs332can be in the relaxed position when the pawl beams330are engaged with the housing teeth224to prevent the knob218from loosening. When the pawl beams330are displaced away from the housing teeth224, the pawl springs332can transition from a relaxed to a flexed state such that the pawl beams330are biased toward the housing teeth224. Also, as shown for example inFIG. 20, in some embodiments, one or more of the pawl teeth338a-bcan engaged the housing teeth224at locations that are radially outside a tangent line that extends from the pivot axis334of the pawl236. In the embodiment ofFIG. 20, the pawl tooth338bcan engage the corresponding housing tooth224at a location on a line that is angled radially outward from the tangent line C by an angle345that is at least about 5° and/or less than or equal to about 15°, and can be about 10° in some embodiments. Thus, when a loosening force is applied to the knob member218(shown by arrow B), a component of the force is directed to urge the pawl236to pivot radially outwardly. Thus, as more loosening force is applied to the knob member218, the pawl teeth338a-bare urged to engage the housing teeth224more firmly. This can prevent the pawls236from unintentionally disengaging from the housing teeth224when a large loosening force is applied. As the pawl236is urged radially outward, the pawl beam can abut against the tips of one or more housing teeth224not engaged by the pawl teeth338a-b, which can prevent the pawl beam330from buckling outwardly and can transfer some of the loosening force into the housing. As discussed above, the surface328aof the pawl base328can abut against the surface324aof the pawl depression324, thereby limiting the amount that the pawl236can rotate radially outwardly.

In some embodiments, multiple pawl teeth338a-bcan be used so that the multiple pawl teeth338a-bsimultaneously engage multiple corresponding housing teeth224so that, when the knob member218is twisted in the loosening direction, the applied force is distributed across multiple teeth per pawl236to prevent the knob member218from rotating in the loosening direction. By distributing the force across multiple teeth, the housing teeth224and pawl teeth338a-bcan relatively small in size while still providing sufficient engagement surface area between the first sides258of the housing teeth224and the first sides344a-bof the pawl teeth338a-b. For example, the engagement of two pawl teeth338a-bwith two consecutive housing teeth224as shown can provide substantially the same engagement surface area for resisting rotation in the loosening direction as a single pawl tooth and housing tooth of twice the size shown. As the size of the housing teeth224is reduced, the number of housing teeth224can increase, and the tightening resolution of the reel204can increase. When the knob member218is advanced by one housing tooth224in the tightening direction (shown by arrow A), the rotational distance that the knob member218travels is reduced as the size of the housing teeth224is reduced and the number of housing teeth224is increased. Thus, by using more, and smaller, housing teeth224, the tightening resolution of the reel204is increased so that the lacing system200can be tightened more precisely to the desired level of tightness. Also, as the size of the housing teeth224is reduced, the distance that the pawls236are displaced in the radially inward direction when the knob member218is tightened is also reduced, thereby making the knob member218easier to rotate in the tightening direction. It is important to note that, in some embodiments, because the multiple pawl teeth338a-bare used, the knob member218can be easily rotated in the tightening direction while strongly resisting rotation in the loosening direction. Although two pawl teeth338a-bare shown per pawl236, additional pawl teeth (e.g., three, four, five, or more) can be used, and, in some embodiments, a single pawl tooth can be used. As shown for example inFIG. 20, in some embodiments, one or more of the pawl teeth338a-band the housing teeth224can be configured to lock together when fully engaged, thereby preventing the pawl236from rotating radially inward unless the knob member218is moved in the tightening direction (shown by arrow A). The surface258of the housing tooth224and the surface344aof the pawl tooth338acan be form an angle343(e.g., by at least about 5° and/or by less than or equal to about 15°, or by about 10°) from a line D, which can be perpendicular to the tangent line C for the pivot axis334of the corresponding pawl236. The line D can be tangent to the arc tracked by the surface344aof the pawl tooth338aas it pivots radially inward. Since the surface258of the housing tooth224is angled towards the pawl beam330, the surface334acan abut against the surface258when a force urges the surface334ato move in the direction of arrow D. Thus, when the pawl tooth338afully engages the housing tooth224such that the surface344aof the pawl tooth338aabuts against the surface258of the housing tooth224, the pawl236is prevented from rotating in the radially inward direction because radially inward rotation would cause the surface344aof the pawl tooth338ato press more firmly against the surface258of the housing tooth224. The angled interface between the surfaces258and344acan also provide a force on the pawl236in the radially outward direction when a loosening force is applied (shown by arrow B). To allow the pawl236to rotate radially inwardly, the pawl236can be shifted in the tightening direction (shown by arrow A) so that the surface344aof the pawl tooth338adisengages from the surface258of the housing tooth224. The other pawl teeth (e.g., pawl tooth338b) can operate similar to the pawl tooth338ato prevent unintentional disengagement of the pawls236.

When the knob member218is rotated in the tightening direction (shown by arrow A), the second sides260of the housing teeth224can slide along the second sides346a-bof the pawl teeth338a-b, causing the pawls236to rotate about the pivot axis (e.g., about the pivot tab336) so that the pawl beams330are displaced radially inwardly away from the housing teeth224, as shown inFIG. 21. As the pawls236rotate, the pawl springs232can be further flexed, for example to a position that is less curved, and the end piece342can slide along the wall of the pawl depression224that is further away from the pawl base328. The curved edge of the generally cylindrically shaped end piece342can provide a small contact area between the end piece342and the wall of the pawl depression224to reduce the amount of friction therebetween as the end piece342slides. Once the tips of the pawl teeth338a-bpass the tips of the housing teeth224, the pawls236can snap radially outwardly to a position similar to that shown inFIG. 20except that the pawls236are advance by one housing tooth224, or one step, in the tightening direction. To tighten the lacing system200, the user can rotate the knob member218in the tightening direction by a desired amount, with the pawls236snapping back after each step to prevent rotation in the loosening direction.

As can be seen inFIGS. 20 and 21, the flanges337of the pawls236can extend radially outwardly past the tips of the housing teeth224, but the flanges337can be positioned near the tops of the pawls236where the flanges337do not contact the housing teeth224. Rather, the flanges337can contact a portion of the wall325of the pawl depressions324, as can be seen inFIG. 19. As the pawls236rotate, the flanges337can roll slightly against the wall of the pawl depressions324to facilitate the desired rotational displacement of the pawls236. The mating of flange337and wall portion325can also assist in maintaining the general radial and axial position of the pawl236in the pawl depression324.

The pawls236can be configured differently than as shown in the illustrated embodiments. For example, in some embodiments, the flexible arm of the pawl spring332can curve toward the pawl beam330(e.g., in the opposite direction as that shown in the illustrated embodiments), and a middle portion of the curved arm of the pawl spring332can ride along a wall of the corresponding depression324. In some embodiments, the curved arm can be configured so that it is more curved when in the more flexed position (e.g., when the pawl beam330is displaced away from the housing teeth224) than when in the less flexed position (e.g., when the pawl beam330is engaged with the housing teeth224). In some embodiments, the flexible arm can be attached to the pawl236at locations other than that shown in the illustrated embodiment. For example, the flexible arm of the pawl spring332can be extend from the end of the pawl beam330that is furthest from the pivot tab336. Other variations are possible. Also, in some embodiments, the pawl spring332can include a flexible arm that extends in generally the opposite direction as the pawl beam330, or generally radially inwardly, or in various other suitable directions so long as the pawl spring332can be flexed to bias the pawl beam330toward the housing teeth224. As discussed above, the pawl spring332can also be made from a leaf spring, or a coil spring, or any other suitable biasing member configured to bias the pawl beam330radially toward the housing teeth224.

Although various embodiments discussed herein include housing teeth224that extend radially inwardly and pawls236configured to be biased radially outwardly toward the housing teeth224, other configurations are possible. For example, the housing teeth224can extend radially outwardly. The housing teeth224can be formed, for example, on the outside surface of the shaft244or similar structure. In these embodiments, the pawls236can be configured to be biased radially inwardly toward the housing teeth224. In some embodiments it may be advantageous to position the housing teeth224nearer to the periphery of the reel204(e.g., as shown in the illustrated embodiments) so that the housing teeth224are disposed along a larger circumference so that more housing teeth224can be included, thereby increasing the tightening resolution (the number of teeth per revolution) of the reel204.

FIG. 22is a top view of the knob core296, the spring bushing298, the fastener300, and the knob spring302in the assembled configurations. With reference now toFIGS. 15,16, and22, the spring bushing298can be generally cylindrical in shape and can have a central opening348formed through the center thereof. The outer surface of the spring busing298can be wider at a top portion349than at a bottom portion351, forming a step350which can be configured to abut against the step318formed in the central opening316of the knob core296when the spring bushing298is fully inserted into the central opening316of the knob core296. In the central opening348that passes through the center of the spring bushing298, the upper portion can be wider than a lower portion, to form a step352.

The head354of the fastener300can abut against the step352in the central opening of the spring bushing298when the fastener300is fully inserted into the central opening348of the spring bushing298. The fastener300can be a screw having a shaft356that includes threads358configured to engage the threads formed in the bore246formed in the shaft244of the housing. In some embodiments, the bore246can include a threaded metal insert or a plastic thread molded as part of the bore246. In some embodiments, the bore246does not have preformed threads, and the threads358of the fastener30can form the threads in the bore the first time that the fastener300is inserted into the bore246. The head354can include a notch360, which can be hexagonally or cross shaped, or otherwise configured to allow a screwdriver or other tool to turn the fastener300. In some embodiments, the knob member218can be coupled to the housing220in some other way, such as using a snap together fastener or rivet or ultrasonic welding. Other alternatives are possible.

The knob spring302can include a pair of opposing engagement portions362a-bwhich can be configured to engage the spring bushing298. A pair of end pieces364a-bcan extend approximately orthogonally from the engagement portions362a-bin an inward direction. An interconnecting portion368, which can be shaped to follow the partial circumference of a circle, can be attached to the engagement portions362a-bby curved connectors370a-b.

The knob spring302can be secured to the knob core296. The wide engagement tab320can be configured to fit between the curved connectors370a-bof the knob spring302, and the narrow engagement tab322can be configured to fit between the end pieces364a-bof the knob spring302to prevent the knob spring302from rotating or otherwise moving with respect to the knob core296. In some embodiments, the wide engagement tab320and/or the narrow engagement tab322can be configured to receive the knob spring302so that the knob spring302is maintained in a slightly flexed configuration with the curved connectors370a-bbearing against the wide engagement tab320and/or the end pieces364a-bbearing against the narrow engagement tab322. In some embodiments, the knob spring302can be prevented from moving axially by the knob cover304when it is attached to the knob core296.

The knob spring302can be configured such that the engagement portions362a-bcan be resiliently moved apart from one other to allow the upper wide portion349of the spring bushing298to pass between the engagement portions362a-b. The spring bushing298can be in a disengaged position, as shown inFIG. 22, where the spring bushing298is located below the engagement portions362a-b. In the engaged position, the upper wide portion349of the spring bushing298can be disposed above the engagement portions362a-bof the knob spring302. The upper wide portion349of the spring bushing can be wider than the distance between the engagement portions362a-bof the knob spring302to prevent the spring bushing from inadvertently transitioning between the engaged and disengaged positions. To transfer the spring bushing298from the engaged to the disengaged positions, a force can be applied, for example by pulling the knob member218in the axial direction away from the base member214, that causes the spring bushing298to press down against the engagement portions362a-bcausing the engagement portions362a-bto resiliently separate from one another until the upper wide portion359of the spring bushing298passes between the engagement portions362a-b. To transfer the spring bushing298from the disengaged to the engaged positions, a force can be applied, for example by pushing the knob member218in the axial direction toward the base member214, that causes the spring bushing298to press up against the engagement portions362a-bcausing the engagement portions362a-bto resiliently separate from one another until the upper wide portion359of the spring bushing298passes between the engagement portions362a-b.

Many variations are possible. For example, in some embodiments, the engagement portions362a-bcan be maintained rigidly in place and the spring bushing298can be made from a resiliently compressible material so that the spring bushing298can transition between the engaged and disengaged positions by resiliently compressing and passing between the engagement portions362a-b. In some embodiments, the fastener300and the spring bushing298can be combined into a single piece. The knob spring302can assume a variety of other shapes and can be attached to the knob core296in a variety of other manners such that the engagement portions262a-bare configured to resiliently flex away from one another. The spring bushing298can be formed in various other shapes than that shown in the illustrated embodiments. In some embodiments, the spring bushing298can be rotationally asymmetrical and can rotate with the knob core296and knob spring302. Thus, in some cases, the spring bushing298can have flat sides that engage the knob spring302along a line instead of just at a point.

With reference now toFIGS. 15 and 16, the knob cover304can be generally disc shaped. The knob cover304can have a domed or generally frustoconical top wall372and a peripheral wall374with a cavity376formed therein. A central opening378can be formed at the center of the top wall372to allow a screwdriver or other tool to be inserted therethrough to engage the notch360on the fastener300. The knob cover304can include securing tabs380and notches382configured to engage the corresponding notches312and protrusions314on the knob core196to secure the knob cover304to the knob core296using a snap-fit connection. The knob cover304can be secured to the knob core296in various other ways such as using an adhesive, a threaded connection, ultrasonic welding, or any other suitable manner. The knob cover304can be either fixedly or removably attached to the knob core296. When the knob cover304is attached to the knob core296, the pawls236, the spring bushing298, the fastener300, and the knob spring302can be enclosed therebetween.

Top tabs384can extend downward from the underside of the top wall372of the knob cover304. The top tabs384can align with the pivot tabs336of the pawls236, and the bottom surfaces of the top tabs384can contact, or nearly contact, the top surfaces of the pivot tabs336of the pawls236to thereby prevent the pawls from moving axially. Many variations are possible. In some embodiments, the pivot tabs336of the pawls236can fit into bores formed in the knob cover304to secure the pawls236and allow the pawls236to pivot about the pivot tabs336.

A recess386can be formed at the center of the cavity376, and the recess386can be configured to receive the upper wide portion349of the spring bushing298when the spring bushing298is in the engaged position.

The peripheral wall374of the knob cover304can include notches388configured to receive corresponding tabs390formed on the inside surface of the knob grip306. The knob grip306can be generally doughnut shaped and can include raised portions392and/or depressions394on the outside surface to facilitate the gripping of the knob member218. In some embodiments, the knob grip306can be omitted or can be divided into intermittent portions disposed about the periphery of the knob cover304. Other variations are possible.

An opening396can be formed in a portion of the top wall372of the knob cover304to provide a view of some of the internal components of the reel204during use, or to provide an exit path for water or other foreign material to exit the reel204. In some embodiments, the opening396can be omitted.

As mentioned above, the knob member218can be axially movable between engaged and disengaged positions.FIG. 23Ais an exploded view of the reel204with the knob member218in the engaged configuration.FIG. 23Bis a cross sectional view of the reel204with the knob member218in the engaged configuration.FIG. 24Ais an exploded view of the reel204with the knob member218in the disengaged configuration.FIG. 24Bis a cross sectional view of the reel204with the knob member218in the disengaged configuration. The knob member218can be secured to the base member214by twisting the fastener300so that the threads358mate with corresponding threads in the bore246formed in the shaft244. In some embodiments, when the fastener300is sufficiently tightened, the portion of the shaft244that extends up past the spool member216can enter into a lower portion of the central opening348formed through the spring bushing298. The bottom edge398of the spring bushing298can abut against, or nearly contact, the annular region400inside of the spool teeth232.

When the knob member218is in the engaged position, as shown inFIGS. 23A and 23B, the spring bushing298and the fastener300can be maintained in an raised position by the knob spring302, as discussed above, so that the bottom edge398of the spring bushing298does not extend past the central opening316of the knob core296. Thus, the knob member218is maintained in the lower engaged position (shown in dotted lines inFIG. 5), with the bottom of the knob core296abutting against, or in close proximity to, the top surface of the spool member216. Thus, when in the engaged position, the knob teeth234engage the spool teeth232, and the pawls236engage the housing teeth224.

When the knob member218is in the disengaged position, as shown inFIGS. 24A and 24B, the spring bushing298and the fastener300can be maintained in a lowered position by the knob spring302, as discussed above, so that the bottom edge398of the spring bushing298extends past the central opening316of the knob core296by at least about 1.0 mm and/or by no more than about 3.0 mm, and in some embodiments by about 2.25 mm, although other configurations outside these ranges are also possible. Since the bottom edge398of the spring bushing298continued to abut against, or nearly contact, the annular region400of the spool member216, the knob member218is raised away from the spool member216and base member214by an amount (e.g., about 2.25 mm) sufficient to cause the knob teeth234to disengage from the spool teeth232and/or to cause the pawls236to disengage from the housing teeth224. In the embodiment shown, when the knob is in the disengaged position, the knob teeth234disengage from the spool teeth232and the pawls236also disengage from the housing teeth224. Thus, in the illustrated disengaged configuration the spool member216can be free to rotate in the loosening direction independent of the knob member218to loosen the lacing system200, and the knob member218can be free to rotate in both the tightening and loosening directions.

Many variations are possible. In some embodiments, when in the disengaged position, the knob teeth234can disengage from the spool teeth232while the pawls236continue to engage the housing teeth224(e.g., if the step340shown inFIG. 17were made larger so that the pawl teeth338a-bextended further downward). In these embodiments, the knob member218can be impeded from rotating in the loosening direction even when in the disengaged position, but the spool member216can be free to rotate in the loosening direction independent of the knob member218to allow the lace206to be withdrawn to loosen the lacing system200. In some embodiments, when in the disengaged position, the knob teeth234can continue to engage the spool teeth232(e.g., if the knob teeth234and/or the spool teeth232were made taller than in the illustrated embodiments) while the pawls236can disengage from the housing teeth224. In these embodiments, the spool member216continues to be coupled to the knob member218even when in the disengaged position, but the knob member218and spool member216are permitted to rotated together in the loosening direction to release the lace206from the reel204to loosen the lacing system200. Other variations are also possible. For example, in some embodiments, the spool member216can be integrally formed with, or fixedly attached to, or removably attached to the knob member218, and the spool teeth232and knob teeth234can be omitted.

As mentioned above, when in the disengaged position, the pawls236can be raised sufficiently to disengage from the housing teeth224. In some embodiments, because the pawls are biased radially outwardly by the pawl springs232, the pawls236can deflect radially outwardly so that portions of the bottom surfaces of the pawls236are positioned above portions of the top surfaces of the housing teeth224. Thus in some embodiments, when the knob member218is transitioned back to the engaged position, the pawls236must be deflected radially inwardly so that they can reengage with the housing teeth224. As also mentioned above, at least a portion of the top surfaces266of the housing teeth224can be angled or beveled and/or at least a portion of the bottom surfaces339of the pawls236can be angled or beveled, so that the downward pressure applied when the knob member is returned to the engaged position can cause the pawls236to deflect radially inwardly to facilitate the reengagement of the pawls236with the housing teeth224. In some embodiments, the pawl depressions324or other portions of the knob member218, can be configured to prevent the pawls236from deflecting radially outwardly past the radial position where the pawls236engage the housing teeth224, thereby reducing or eliminating the need to deflect the pawls236inwardly when transitioning the knob member218to the engaged position.

The knob member218can be transitioned from the engaged position to the disengaged position by pulling the knob member218axially away from the base member214with enough force to cause the spring bushing298to displace the knob spring302and pass therethrough. To transition the knob member218from the disengaged position to the engaged position the knob member218can be pushed in the axial direction toward the base member214with enough force to cause the spring bushing298to displace the knob spring302and pass therethrough.

The radial engagement of the pawls236with the housing teeth224can reduce or eliminate the occurrence of unintentionally transitioning the knob member218from the engaged to disengaged positions by applying force to tend to twist the knob member218in the loosening direction. If the lace206is pulled, it can impart a force tending to twist the spool member216in the loosening direction, and the force can be transferred to the knob218via the spool teeth232and knob teeth234, and the pawls236can distributed the force radially among a certain number of the housing teeth224. Because the pawls236engage the housing teeth radially, not axially, and because the pawls236are configured to be displaced radially (when tightening the reel204), substantially none of the force is applied to the knob218in the axial direction. Thus, the radial pawls236do not impart any substantial force in the direction of the axial direction that would tend to separate the spool teeth232from the knob teeth234which can lead to unintentional disengagement of the knob member218and/or unintentional loosening of the spool member216. Thus, the reel204can be configured to withstand greater amounts of force applied to pull on the lace206or applied to try and twist the knob member218in the loosening direction without unintentionally causing the knob member218to disengage than a reel204in which the pawls axially engage the housing teeth and the pawls are configured to displace axially during tightening.

Also, in some embodiments, the force applied to the pawls236when the knob218is twisted in the loosening direction is born by the pawl beams330such that substantially none of the force is transferred to the pawl springs332. Thus, the pawl springs332can be configured to be easily flexible while the pawl beams330can be configured to be substantially rigid. Therefore, the pawls236can be configured to resist a relatively large amount of force applied to twist the knob member218in the loosening direction because that force is born by the rigid pawl beams330, while the pawls can also be configured to rotate radially when a relatively small force is applied to twist the knob member218in the tightening direction because that force is transferred to the flexible pawl springs332.

The components of the lacing systems described herein can be formed from any suitable material such as, but not limited to, plastic, carbon or other fiber reinforced plastic, aluminum, steel, rubber, or any other suitable material or combination of such materials. In some embodiments, the base member214, spool member216, knob core296, pawls236, spring bushing298, knob cover304, lace guides, or any other suitable components described herein can be injection molded or otherwise formed from any suitable polymeric material, such as nylon, PVC or PET. Some of the components described herein can be formed from a lubricious plastic such as PTFE, or other material useful in reducing the friction between a lace and such components as desired. Additionally, some of the components described herein can be coated or layered with a lubricious material to reduce the friction with interacting components or parts. The fastener300, and the knob spring302can be made from a metal (e.g., aluminum or steel), but other materials can also be used such as plastics. The knob grip306can be formed from rubber, or latex, or silicon, or any other material to facilitate the gripping of the knob member218.

FIG. 25is a perspective view of an alternative embodiment of a base member414which can be used in place of the base member214discussed above. The base member414can include a housing420and a mounting flange422and can be generally similar to the base member214described above, except that the lace holes426a-bcan be configured to direct the lace generally radially away from the base member414rather than axially away from the base member214as shown, for example, inFIG. 2. Also, the lace holes426a-bare placed generally on the same side of the base member414, rather than on opposite ends as in the base member214discussed above. Many variations are possible depending on the particular application to which the lacing system is applied. For example, in some embodiments, the base member can include only one lace hole and only one end of the lace can enter the housing and attach to the spool member. In these embodiments, the other end of the lace can attach to the base member or to the article being tightened.

FIG. 26is a cross sectional view of another embodiment of a knob core596which can be used in a reel that can be similar in many ways to the reel204described herein. The knob core596can include pawls536which can be integrally formed with the knob core596to simplify construction and assembly of the reel. In other embodiments, the pawls536can be attached to the knob core596in any suitable manner. The pawls536can include pawl arms532which can be made of a material, thickness, and length so as to be flexible to allow the pawls536to be displaced radially inwardly by housing teeth as the knob core596is rotated in the tightening direction (shown by arrow A) in a manner similar to that described above. The pawls536can include pawl teeth538a-bformed at the ends of the pawl arms532. In the illustrated embodiment two pawl teeth538a-bare used per pawl536, but any other suitable number of pawl teeth538a-bcan be used.

When the knob core596is twisted in the loosening direction (shown by arrow B), the pawl teeth538a-bcan bear against housing teeth (not shown inFIG. 26) to prevent the knob core596from rotating in the loosening direction. The force arrows drawn inFIG. 26illustrate the directions in which the force is distributed radially. As the pawl teeth538a-bbear against the housing teeth, a force is applied from the pawl teeth538a-bto the housing teeth as shown. The pawl arms532can be curved as shown so that, when the pawl teeth538a-bbear against the housing teeth, the pawl arms532tend to flex or buckle radially outwardly as shown by arrows inFIG. 26. The pawls536can be configured such that the housing teeth abut against the pawl arms532such that, as the pawl arms532attempt to flex or buckle radially outwardly, they bear against the tips of the housing teeth, distribute the force radially to the housing teeth, and are prevented from buckling. In some embodiments, the housing teeth can substantially prevented the pawl arms532from moving radially outwardly. Because pawls536engage the housing teeth radially, not axially, and because the pawls536are configured to be displaced radially, not axially, during tightening, substantially none of the force applied when twisting in the loosening direction is applied axially thereby reducing or eliminating the occurrence of unintentional axial movement of the knob core596from the engaged position to the disengage position.

Although various embodiments of lacing systems are described herein, the various components, features, or other aspects of the embodiments of the lacing systems described herein can be combined or interchanged to form additional embodiments of lacing systems not explicitly described herein, all of which are contemplated as being a part of the present disclosure. In addition, while a number of variations have been shown and described in detail, other modifications, which are within the scope of the this disclosure, will be readily apparent to those of skill in the art based upon this disclosure. Thus, it is intended that the scope of the disclosure should not be limited by the particular disclosed embodiments described above.