Reel based closure system employing a friction based tension mechanism

A reel based tensioning device includes a housing, a spool that is rotatably positioned within the housing, and a knob member that is operably coupled with the spool to cause the spool to rotate in a first direction within the housing and thereby wind a tension member about the spool. The reel based tensioning device also includes a load holding mechanism that is coupled with the spool and that is configured to rotate the spool in the first direction within the housing and to prevent rotation of the spool in a second direction to prevent unwinding of the tension member from about the spool. The reel based tensioning device further includes an audible component that is configured to produce an audible noise responsive to operation of the knob member to signal an adjustment of the tension member.

BACKGROUND OF THE INVENTION

The present disclosure is related to reel based closure devices for various articles, such as braces, medical devices, shoes, clothing, apparel, and the like. Such articles typically include some closure system, which allows the article to be placed about a body part and closed or tightened about the body part. The closure systems are typically used to maintain or secure the article about the body part. For example, shoes are typically placed over an individual's foot and the shoelace is tensioned and tied to close and secure the shoe about the foot. Conventional closure systems have been modified in an effort to increase the fit and/or comfort of the article about the body part. For example, shoe lacing configurations and/or patterns have been modified in an attempt to increase the fit and/or comfort of wearing shoes. Conventional closure systems have also been modified in an effort to decrease the time in which an article may be closed and secured about the body part. These modifications have resulted in the use of various pull cords, straps, and tensioning devices that enable the article to be quickly closed and secured to the foot.

BRIEF DESCRIPTION OF THE INVENTION

The embodiments described herein provide reel based tensioning devices, and components therefor, that may be used to tension a lace or tension member and thereby tighten an article or other item. According to one aspect, an insert molded component for a reel based tensioning device includes a base member of a reel based tensioning device and a fabric material. The base member is typically made of a polymer material and includes a top end and a bottom end with a bottom surface. The base member has an interior cavity within which one or more components of the reel based tensioning device are positionable. The fabric material is substantially flush with the bottom surface of the base member and extends laterally from at least a portion of an outer periphery of the bottom end of the base member. The base member is insert molded onto the fabric material by injecting the polymer material through the fabric material so that when the insert molded component is formed, the fabric material is disposed within at least a portion of the base member with the polymer material of the least a portion of the base member being disposed on opposite sides of the fabric material.

According to another aspect, a component of a reel based tensioning system includes a first component that is made of a polymer material and that includes a top end, a bottom end, and an interior cavity within which a second component of the reel based tensioning system is positionable. The component also includes a fabric material that is positioned near the bottom end of the first component and that extends laterally from at least a portion of an outer periphery of the first component. The fabric material is integrally coupled with the first component by injecting the polymer material of the first component through the fabric material so that the polymer material of at least a portion of the first component is saturated or impregnated through the fabric material and so that the polymer material of the at least a portion of the first component extends axially bellow a bottom surface of the fabric material and axially above a top surface of the fabric material.

According to another aspect, a method of forming a component of a reel based tensioning system includes providing a fabric material, positioning the fabric material within a die or mold, and injecting a polymer material through the fabric material so that the polymer material fills a void or space within the die or mold that defines a shape of a first component of the reel based tensioning system. The method also includes cooling the polymer material so that the polymer material hardens and forms the first component of the reel based tensioning system. The polymer material of at least a portion of the first component is saturated or impregnated through the fabric material so that the polymer material of the at least a portion of the first component extends axially bellow a bottom surface of the fabric material and axially above a top surface of the fabric material.

According to another aspect, a reel based tensioning device includes a housing having an interior region and a spool positioned within the interior region of the housing and rotatable relative thereto. The reel based tensioning device also includes a knob member that is operably coupled with the spool to cause the spool to rotate in a first direction within the interior region of the housing to wind a tension member about the spool and thereby tension the tension member. The reel based tensioning device further includes a load holding mechanism that is coupled with the spool and that is configured to allow rotation of the spool in the first direction within the interior region of the housing and to prevent rotation of the spool in a second direction within the interior region of the housing to prevent unwinding of the tension member from about the spool. The reel based tensioning device additionally includes an audible component that is separate from the load holding mechanism and that is configured to produce an audible noise in response to operation of the knob member to audibly signal an adjustment in tension of the tension member.

According to another aspect, a reel based tensioning device includes a housing, a spool rotatably positioned within the housing, a knob member that is operably coupled with the spool to cause the spool to rotate in a first direction within the housing to wind a tension member about the spool, a load holding mechanism that is coupled with the spool and configured to allow rotation of the spool in the first direction within the housing and to prevent rotation of the spool in a second direction within the housing to prevent unwinding of the tension member from about the spool, and an audible component that is configured to produce an audible noise responsive to operation of the knob member to signal an adjustment of the tension member.

According to another aspect, a method of configuring a reel based tensioning device includes providing the reel based tensioning device, in which the reel based tensioning device includes a housing, a spool rotatably positioned within the housing, a knob member that is operably coupled with the spool to cause the spool to rotate in a first direction within the housing to wind a tension member about the spool, and a load holding mechanism that is coupled with the spool and that is configured to allow rotation of the spool in the first direction within the housing and to prevent rotation of the spool in a second direction within the housing to prevent unwinding of the tension member from about the spool. The method also includes coupling an audible component with the reel based tensioning device, in which the audible component is configured to produce an audible noise responsive to operation of the knob member to signal an adjustment of the tension member.

According to another aspect, a reel based tensioning device for tightening an article includes a housing having an interior region, a spool positioned within the interior region of the housing and rotatable relative thereto, a knob member that is operably coupled with the spool to cause the spool to rotate within the interior region of the housing, and a load holding mechanism that is coupled with the spool. The load holding mechanism includes a spring that frictionally engages with a cylindrical member to prevent rotation of the spool within the interior region of the housing responsive to forces imparted on the spool from a source other than the knob member, such as tension in the tension member that imparts a rotational force on the spool. The knob is operationally coupled with the load holding mechanism so that a rotation of the knob in a first direction reduces the frictional engagement of the spring and cylindrical member in order to allow rotation of the spool in the first direction within the interior region of the housing and thereby wind a tension member about the spool. The knob is also operationally coupled with the load holding mechanism so that a rotation of the knob in a second direction also reduces the frictional engagement of the spring and cylindrical member in order to allow rotation of the spool in the second direction within the interior region of the housing and thereby unwind the tension member from about the spool.

According to another aspect, a reel based tensioning device includes a housing, a spool that is rotatably positioned within the housing, a knob member that is operably coupled with the spool to cause the spool to rotate within the housing, and a load holding mechanism that includes a spring that frictionally engages with a cylindrical member to prevent unwanted rotation of the spool within the housing. The knob member is operationally coupled with the load holding mechanism so that a first operation of the knob member reduces the frictional engagement of the spring and cylindrical member to allow rotation of the spool within the housing to wind a tension member about the spool and so that a second operation of the knob member also reduces the frictional engagement of the spring and cylindrical member to allow rotation of the spool within the housing to unwind the tension member from about the spool.

According to another aspect, a method for assembly an article with a reel based tensioning device includes providing a reel based tensioning device, in which the reel based tensioning device includes a housing, a spool that is rotatably positioned within the housing, a knob member that is operably coupled with the spool to cause the spool to rotate within the housing, and a load holding mechanism that includes a spring that frictionally engages with a cylindrical member to prevent unwanted rotation of the spool within the housing. The knob member is operationally coupled with the load holding mechanism so that a first operation of the knob member reduces the frictional engagement of the spring and cylindrical member to allow rotation of the spool within the housing to wind a tension member about the spool and a second operation of the knob member also reduces the frictional engagement of the spring and cylindrical member to allow rotation of the spool within the housing to unwind the tension member from about the spool. The method also includes coupling the reel based tensioning device member with the article.

DETAILED DESCRIPTION OF THE INVENTION

The embodiments herein describe reel based closure or tensioning devices that may be used to tension a lace or tension member and thereby tighten an article or other item. The reel based tensioning devices are also referred to herein as reel systems or simply closure devices. The article may be a variety of items including a pack (i.e., back pack, book bag, etc.), an article of clothing (i.e., hats, gloves, belt, etc.), sports apparel (boots, snowboard boots, ski boots, etc.), medical braces (i.e., back braces, knee braces, wrist brace, ankle brace, etc.), and/or various other items or apparel. A specific embodiment in which the closure system may be employed involves footwear, such as shoes, boots, sandals, etc.

The reel systems herein employ friction based tension adjustment mechanisms, which are used to tension a lace, cord, or tension member (hereinafter tension member) and to maintain the tension of the tension member. The friction based tension adjustment mechanisms described herein employ a load holding mechanism having a spring (e.g., a coil spring) that frictionally engages with a cylindrical member, such as a boss or hub, in order to provide a load holding function that maintains the tension in the tension member. Specifically, the frictional engagement of the spring and the cylindrical member is employed to prevent unwanted rotation of a spool within the housing. Since the reel systems are used to maintain tension in the tension member, unwanted rotation of the spool means any rotation of the spool that is not initiated by a user and that would result in loosening or un-tensioning of the tension member. Stated differently, the system is designed so that the spool will rotate only in response to an action by the user to loosen or un-tension the lace, which commonly involves a rotation of a knob component of the reel system in a loosening direction, but could also involve other actions, such as operating a lever, pressing a button, pulling axially upward on the knob, and the like. Absent this action by the user, the spring and the cylindrical member are designed to frictionally engage and prevent rotation of the spool within the housing.

The reel system typically includes a knob that is designed to be grasped and rotated by a user. The knob member is operationally coupled with the load holding mechanism so that a first operation of the knob member (e.g., rotation of the knob in a tightening direction) reduces the frictional engagement of the spring and cylindrical member to allow rotation of the spool within the housing to wind the tension member about the spool. The knob member is also operationally coupled with the load holding mechanism so that a second operation of the knob member (e.g., rotation of the knob in a loosening direction) reduces the frictional engagement of the spring and cylindrical member to allow rotation of the spool within the housing to unwind the tension member from about the spool.

In an exemplary embodiment, the coil spring is positioned or wound about an exterior of a hub member or central cylindrical boss. The coil spring is configured to constrict about the hub member or central cylindrical boss in order to provide the load holding function. In one embodiment, the hub member or central cylindrical boss may include an upper hub member that is fixedly secured to the spool and a lower hub member that is fixedly secured to the housing. The upper hub member may have a diameter that is slightly larger than a diameter of the lower hub member. In such embodiments, a distal end of the upper hub member that interfaces with the lower hub member may be tapered. In another embodiment, the hub member or central cylindrical boss may be an inner hub member and the reel system may also include an outer hub member that is disposed over the inner hub member and that is operationally coupled with the knob member and the spring so that a rotation of the knob member in a loosening direction reduces the frictional engagement of the spring and the inner hub member. In such embodiments, the outer hub member may be coupled with the knob member such that rotation of the knob member in the loosening direction effects a rotation of the outer hub in the loosening direction. The spring may include a tang that is coupled with the outer hub member so that rotation of the outer hub member in the loosening direction effects a widening of a diameter of the spring thereby reducing the frictional engagement of the spring and the inner hub member. In yet another embodiment, the coil spring may be positioned within a cylindrical channel or recess of a boss or hub. In such embodiments, the coil spring is biased to flex radially outward and into frictional engagement with an interior wall of the cylindrical channel or recess in order to provide the load holding function.

The friction based tension adjustment mechanism eliminates the need for pawls or flexible arms that are commonly used in conventional systems to provide the load holding functions. In such conventional systems, a pawl or arm commonly engages with teeth in order to provide the load holding function. The pawl/arm and teeth are often sloped or configured to enable a one-way motion of the pawl/arm and thereby the reel based device, such as rotation of a knob in a tightening direction. The pawl/arm and teeth lockingly engage when the knob is rotated in an opposite direction in order to prevent rotation of one or more components of the system that would loosen the tension in the tension member. The embodiments herein may be entirely free of a pawl or arm that functions to provide load holding capabilities. In other embodiments, the reel system may include a combination of a friction based mechanism and a pawl or arm in order to provide the load holding functions.

The load holding mechanism described herein (i.e., the spring and hub member) may not produce an audible noise that is detectable by a human ear. As such, the reel system may include an audible component that is configured to produce an audible noise responsive to operation of the knob member to signal an adjustment of the tension member. The audible component may be configured to produce an audible noise responsive to tensioning of the tension member and to produce an audible noise responsive to loosening of the tension member. The audible noise that is produced responsive to tensioning of the tension member may be different than the audible noise responsive to loosening of the tension member. The audible component may be coupled with a top surface of the spool.

While the systems herein are commonly devoid of a load holding pawl or arm, in the exemplary embodiment, a separate pawl system, member, or beam may be used to produce the audible noise or sound when the system is operated. For example, the pawl system, member, or beam may be used primarily to produce a click sound when the knob is rotated, which audibly indicates to a user that the system is being used to tension or loosen the tension member. The pawl system, member, or beam may provide audible feedback that users of the system may expect and/or desire. The pawl system, member, or beam may be incapable of preventing rotation of the spool within the housing when an appreciable rotational force is imposed on the spool via the tension member or knob member. For example, when the user rotates the knob member in a loosening direction, the pawl system, member, or beam may not appreciably impede the rotation of the knob member.

Additional features and aspects of the reel based closure devices will be evident with references to the description of the several drawings which is provided herein below.

FIG. 1illustrates an assembled perspective view of the reel system100. The assembled reel system100shows a knob170attached to a housing102, which is typically coupled with a base member220. The housing102is coupled with the base member220in a manner that allows the housing102to be detached or removed from the base member220. Coupling of the housing102and base member is achieved via engagement of mating features that are positioned on both components.FIG. 1illustrates a lip or flange member106that is positionable within a front tab222of the base member220to couple the front portion of the housing102to the base member220.FIG. 16illustrates tabs110that are positioned on an opposite side of the housing102. The tabs110are designed to fit within corresponding slots on an interior surface of a wall224that partially surrounds the periphery of the base member220.FIG. 16also illustrates lace ports104of the housing102. The lace ports include an opening105within which the tension member is inserted to allow the tension member to access the interior of the housing102. As illustrated inFIG. 17, the base member220includes open portions or areas on opposing sides of the front tab222that are shaped and sized to accommodate the lace ports104, which provides a visual appearance of the base member220and housing102being a unitary component.

The housing102is shaped so that it corresponds with an outer surface of the base member220and with the outer surface of the knob170. For example, when the housing102is attached to the base member220, the outer surfaces of these components align so that they appear as a continuous or matching surface. The matching outer surfaces of the housing102and the base member220helps to conceal or hide the edges of both components. In this manner, the user does not readily perceive the separate edges of the components, but rather visually perceives the separate components as an integral unit. The outer surface of the housing102similarly aligns with the knob170so that the outer surfaces appear to flow together. The alignment of the knob170and outer surface of the housing102also eliminates or minimizes ridges or edges that could catch on surrounding objects and open the system or separate the knob170from the housing102. The shape of the housing102, knob170, and base member220provides a visually appealing look that users may desire.

The knob170is coupled with the housing102via a snap engagement or fit. Specifically, an inner surface of the knob170include radially inwardly protruding tabs176that are configured to snap over a radially outwardly protruding rib114of the housing102. The knob170may flex radially outward slightly as the two components are snap fit together. The snap fit engagement or coupling allows the components to be attached together without the use of a screw, bolt, or other similar mechanical fastener. An exemplary embodiment of a snap fit coupling of a knob and housing is further described in U.S. patent application Ser. No. 14/297,047, filed Jun. 5, 2014, and entitled “Integrated Closure Device Components and Methods,” the entire disclosure of which is incorporated by reference herein.

FIGS. 1 and 5illustrate the knob170having a textured or patterned outer rim173, which in some instances may have a knurled configuration. The textured or patterned outer rim may enhance the grip surface of the rim173of the knob170and/or may be employed for aesthetic appeal. In some instances, the knob170may be made of a metal material, such as aluminum or stainless steel. In such instances, the textured or patterned outer rim173may significantly enhance the grip properties of the knob170. In other instances, the knob170may be made of plastic materials, such as polypropylene, polyethylene, nylon, and the like.

FIGS. 2 and 3illustrate exploded perspective view of the reel system100. The internal components of the reel system100are visible inFIGS. 2 and 3. The term “internal components” implies the components of the system that are disposed within an interior region116of the housing102and axially below the knob170so that in the assembled view, the internal components are not visible. The internal components include a spool140, a friction based load holding mechanism120, an audible feedback assembly160, and a stop cord or mechanism230(seeFIG. 20). Each of these components is described in greater detail in relation toFIGS. 2-20, which provide detailed perspective views of the various components.

The spool140is rotatably positioned within the interior region116of the housing102. A detailed perspective view of the spool140is illustrated inFIG. 9. The spool140is configured to rotate around a cylindrical coupling post190that attaches to a central boss115of the housing102. The cylindrical coupling post190is inserted through a central aperture148of the spool140and attaches to the central boss115of the housing102by inserting or press fitting a distal end of the cylindrical coupling post190within an aperture of the housing's central boss115(seeFIG. 16).FIG. 16illustrates the cylindrical coupling post190press fit or inserted within the aperture of the central boss115. The cylindrical coupling post190may be secured to the central boss115via an interference fit, adhesive bonding, welding (RF, sonic, etc.), and the like. The spool's aperture148is sufficiently large so as to minimize frictional forces between the spool140and cylindrical coupling post190and thereby enable the spool140to freely rotate about the cylindrical coupling post190within the interior region116of the housing102.

The spool's aperture148is centrally positioned within a recessed portion of the upper surface of the spool140. The recessed portion of the upper surface of the spool140is shaped and sized to accommodate a cap of the cylindrical coupling post190. When the cap of the cylindrical coupling post190is positioned within the recessed portion of the spool140, an upper surface of the cap may align with the upper surface of the spool140.

The spool140includes a lace take up region, such as an annular channel144, around which the tension member (not shown) is wound and unwound in order to tension and loosen the tension member. The spool140is operationally coupled with the knob170so that rotation of the knob170in a tightening direction (e.g., clockwise) and a loosening direction (e.g., counter-clockwise) effects a corresponding rotation of the spool140within the interior region116of the housing102. The knob170includes one or more drive components or tabs174that are positioned within a window150of the spool140. In the illustrated embodiment, the reel system100includes three drive tabs174and three windows150, although more or fewer of these components may be employed as desired.

The drive tabs174are sized smaller than the windows150so that the drive tabs174are rotatable by some amount within the windows150between opposing inner sides or edges152of the window150. The relative rotation of the drive tabs174within the windows150allows the knob170to be rotated about the housing102by some amount without effecting a tightening or loosening of the tension member. The smaller sized drive tabs174facilitate in releasing the friction based load holding mechanism120as described herein.FIGS. 12 and 13illustrate the drive tabs174rotating between the opposing sides152of the windows150and being used in a manner that enables tensioning and loosening of the tension member by causing the spool140to rotate within the interior region116of the housing102.

The bottom or rear surface of the spool140includes a large cylindrical opening or channel142within which the friction based load holding mechanism120is positioned. As illustrated inFIG. 10, the friction based load holding mechanism120includes an upper hub126, a lower hub122, a coil spring134, and a release sleeve134, all or most of which are coaxially aligned and positioned within the opening or channel142of the spool140. The upper hub126, lower hub122, and release sleeve130all include axially extending teeth. Specifically, the upper hub126includes axially extending teeth128, the lower hub includes axially extending teeth124, and the release sleeve130includes axially extending teeth132. The axially extending teeth,128and124, of the upper hub126and lower hub122are oriented so that the teeth extend in opposing directions. The release sleeve130is oriented so that its axially extending teeth132extend in the same direction as the axially extending teeth128of the upper hub126.

The upper hub126is positioned within the cylindrical opening142of the spool140so that its axially extending teeth128are inserted within corresponding apertures158of the spool140, which locks or fixedly secures the upper hub126to the spool140. Fixedly securing the upper hub126to the spool140means that the upper hub126does not translate or rotate relative to the spool140. Rather, rotational motion or movement of the spool140causes a corresponding rotational motion or movement of the upper hub126since the two components are fixedly secured together. The lower hub122is similarly positioned within the interior region116of the housing102so that its axial extending teeth124are inserted within corresponding apertures107of the housing102, which locks or fixedly secures the lower hub122to the housing102. When coupled with the base member220, the housing102is fixed in position relative to the base member220. Since the lower hub122is locked or fixedly secured to the housing102, the lower hub122is fixed in position relative to the base member and housing and thus, the lower hub122is not rotatable or translatable relative to the reel system100.

The coil spring134is positioned over the upper hub126and the lower hub122. The release sleeve130is in turn positioned over the coil spring134so that the coil spring134, the upper hub126, and the lower hub112are positioned within the cylindrically interior region of the release sleeve130. The coil spring134surrounds the upper hub126and the lower hub122in a manner that allows the coil spring134to constrict about the outer surfaces of these hubs,126and122. Specifically, the coil spring134has an inner diameter that is approximately the same as, or slightly smaller, than an outer diameter of the upper hub126and the lower hub122. The coil spring134frictionally engages with the upper hub126and the lower hub122by constricting about the outer surface of said hubs,122and126. The frictional engagement of the coil spring134and the upper and lower hubs,126and122, provides the load holding property or function of the friction based load holding mechanism120. Specifically, the constriction of the coil spring134about the upper hub126and the lower hub122locks or secures the upper hub126and lower hub122in relation to one another by preventing the upper hub126from rotating about or relative to the lower hub122. Locking the upper hub126and the lower hub122together in this manner locks the spool140in position relative to the housing102since the spool140is fixedly secured to the upper hub126. This prevents the spool140from spinning or rotating within the interior region116of the housing102, which maintains a tension that exists in the tension member.

The coil spring134is designed so that when the knob170is rotated in the tightening direction (e.g., Arrow A inFIG. 12), the coil spring134is able to rotate about the lower hub122, which is fixed in positon about the housing102. The coil spring134typically stays fixed in position about the upper hub126and rotates in the tightening direction along with the upper hub126, the release sleeve130, the spool140, and the knob170. Maintaining a proper alignment of the upper hub126, the coil spring134, and the release sleeve130is important in delivering a consistent and repeatable tensioning and loosening feel and performance of the reel system100as described herein. Rotation of these components in the tightening direction causes the tension member to be wound about the annular channel144of the spool140, which increases the tension in the tension member. When rotation of the knob170in the tightening direction ceases, the coil spring134constricts about the upper and lower hubs,126and122, thereby locking or securing these components together and preventing rotation of the spool140and other components in the loosening direction (e.g., Arrow B ofFIG. 13). The tension in the tension member typically biases the spool140toward rotation in the loosening direction, which increases the frictional engagement of the coil spring134and upper and lower hubs,126and122. The increased frictional engagement of these components further locks, or more fixedly secures, the upper and lower hubs,126and122, together.

The release sleeve130is used to adjust the frictional engagement of the coil spring134about the upper and lower hubs,126and122, in order to allow the hubs,126and122, to rotate relative to one another and thereby allow the spool140to spin within the interior region116of the housing102. Specifically, the release sleeve130is operationally coupled with the knob170so that rotation of the knob170in the loosening direction causes a lower portion of the release sleeve130to rotate in the loosening direction. As illustrated inFIG. 13, as the knob170is rotated in the loosening direction, the drive tabs174of the knob170engage the axially extending teeth132of the release sleeve130, which causes the release sleeve130to rotate in the loosening direction.

As illustrated inFIG. 11, an opposite end of the release sleeve130is attached to a radially extending tang136of the coil spring134so that rotation of the release sleeve130in the loosening direction presses on the tang136which causes the coil spring134to open slightly. Specifically, as the release sleeve130rotates in the loosening direction, the tang136is pressed and rotated in the loosening direction, which causes the lower coil portions of the coil spring134to radially open or widen, thereby reducing the frictional engagement of the lower coil portions and the lower hub122. The reduced frictional engagement of the coil spring134and lower hub122allows the lower coil portions of the coil spring134to rotate about the lower hub122in the loosening direction.

The upper portions of the coil spring134remain fixed in position about the upper hub126so that the upper portions of the coil spring134do not rotate about, or relative to, the upper hub126. Since the lower portions of the coil spring134are rotatable about the lower hub122via the release sleeve130, the upper hub126and coil spring134may be rotated in the loosening direction. In this manner the release sleeve130enables the upper hub126to be unlocked or uncoupled from the lower hub122, which allows the upper hub126and coil spring134to be rotated in the loosening direction in response to rotation of the knob170in the loosening direction. Since the upper hub126is attached to the spool140, uncoupling the upper and lower hubs,126and122, allows the spool140to be rotated in the loosening direction in response to rotation of the knob170in the loosening direction, which unwinds the tension member from the annular channel144and thereby reduces tension in the tension member. When rotation of the knob170in the loosening direction ceases, the lower portion of the coil spring134constricts about the lower hub122, which locks or couples the upper and lower hubs,126and122, and thereby prevents further rotation of the upper hub126, the coil spring134, and the spool140in the loosening direction.

The release sleeve130is sized radially larger than the coil spring134to ensure that the release sleeve130does not frictionally engage with, or minimally engages with, the coil spring134, which engagement may impede rotation of the release sleeve130relative to the coil spring134.

As briefly described above, it is desirable to maintain an orientation of the upper hub126, the coil spring134, the release sleeve130, and the spool140. A proper orientation of these components is important to ensure that rotation of the knob170in the loosening direction causes the release sleeve130to engage the tang136in a consistent and repeatable manner, which ensures that the tightening and loosening of the tension member remains relatively constant. As illustrated inFIGS. 12 and 13, the axially extending teeth132and the drive tabs174are positioned within the windows150of the spool140. In order to achieve a repeatable and consistent engagement of the tang136, it is important to maintain the orientation or relative positions of the axially extending teeth132and the drive tabs174within the window150. Otherwise, the drive tabs174will not properly engage the axially extending teeth132of the release sleeve130to cause the release sleeve130to rotate and open the lower coil portions of the coil spring134as described above.

To maintain the orientation of these components, it is important that the upper coil portions of the coil spring134remain fixed about the upper hub126. Specifically, it is important that the coil spring134does not rotate relative to the upper hub126, but rather only rotates relative to or about the lower hub122. To ensure that the coil spring134rotates about the lower hub122only and remains fixed or secured to the upper hub126, one or more of the following upper and lower hub configurations may be employed: the upper hub126may have a slightly larger diameter than the lower hub122, the upper hub126may be made of a material having a greater coefficient of friction than the lower hub122, the lower hub122may have a surface finish that substantially reduces the frictional coefficient in comparison with the upper hub126. Any combination of these options may be employed to ensure that the coil spring134only rotates about the lower hub122.

For example, as illustrated inFIGS. 6 and 7, the upper hub126may have a diameter D1that is larger than a diameter D2of the lower hub122. The larger diameter D1of the upper hub126ensures that the coil spring134constricts about and is more frictionally engaged with the upper hub126than the lower hub122. In some embodiments, the difference in diameter between the upper and lower hubs,126and122, is approximately 2 mm. The 2 mm diameter difference is sufficient to ensure that the coil spring134remains frictionally engaged with, and secured to, the upper hub126without significantly affecting the load holding power of the system, which may occur when the difference in diameter between the upper hub126and the lower hub122is too substantial. If the difference in diameter between the upper hub126and the lower hub122is too great, the coil spring134may not be able to sufficiently constrict about the lower hub122and thus, the coil spring134may not be able to lock or secure the upper and lower hubs,126and122, together.

To help ensure that the coil spring134is able to properly constrict about the different sized hubs, the upper hub126includes a tapered distal end127, which provides a transition between the larger diameter upper hub126and the smaller diameter lower hub122. The tapered distal end127ensures that a rough step or abrupt edge is not formed at an interface between the two hubs, which may negatively affect the holding power of the reel system100by limiting the ability of the coil spring134to grip and constrict about the outer surface of the lower hub122. The tapered distal end127allows the coil spring134to constrict and grip about the outer surface of the lower hub122despite the difference in size of the upper and lower hub. In addition, the upper hub126may be made of a material having a greater coefficient of friction than the lower hub122. For example, the upper hub126may be made of aluminum while the lower hub122is made of brass or bronze. The surface finish of the lower hub122may further, or alternatively, reduce the frictional coefficient of the lower hub122. For example, the lower hub122may have a polished surface finish in comparison with the upper hub126, which may substantially reduce the frictional coefficient of the lower hub122.

To maintain the orientation of the components, it is also important to ensure a proper alignment of the release sleeve130and the coil spring's tang136. The alignment of the release sleeve130and tang136is important to ensure that rotation of the release sleeve130in the loosening direction immediately engages the tang136. In some instances, the distal end of the release sleeve130may include a notch or slot within which the tang136is positioned. In the instant embodiment, however, the tang136is inserted directly into the distal end of the release sleeve130as shown inFIG. 11. One method of directly inserting the tang136into the distal end of the release sleeve130is via heat staking the tang136into the release sleeve130. Directly inserting the tang136into the release sleeve130eliminates or substantially minimizes any issues associated with manufacturing tolerances, which may vary the relative position of the tang136about the release sleeve130and significantly affect how the coil spring134opens in response to counter-rotation of the knob170and release sleeve130.

Since the coil spring134is wrapped around the upper and lower hubs multiple times, any variance in the diameter of either hub,126and122, can significantly affect the position of the tang136in relation to the release sleeve130. For example, a change in diameter of either hub results in a change in the position of the tang136relative to the release sleeve130that can be modeled by the equation V=NπΔD, where V is the variance in the position of the tang136about release sleeve130, N is the number of wrappings of the coil spring134, and ΔD is the change in the diameter of either hub. It has been observed that small variations in the diameter of either or both hubs,126and122, can change the position of the tang136by up to 1 mm, which can greatly affect how much the coil spring134opens or widens in response to counter-rotation of the release sleeve130. Directly inserting the tang136into the distal end of the release sleeve130, via heat staking or some other method, negates the affects that any variance in the components of the reel system100may have. Rather, directly inserting the tang136into the release sleeve130ensures a proper and precise alignment regardless of any variance experienced in the system. Eliminating or reducing the variance in the positioning of the tang136about the release sleeve130typically results in a more consistent and repeatable system performance and feel in tensioning and loosening the tension member.

In some embodiments, the coil spring134may be wrapped about the upper and lower hubs,126and122, about 7 times.

FIGS. 12 and 13illustrate the interaction of the knob170, the spool140, and the release sleeve130in adjusting the tension of a tension member.FIG. 12illustrates these components being used to increase the tension of the tension member by winding the tension member around the spool's annular channel144whileFIG. 13illustrates these components being used to reduce the tension of the tension member by unwinding the tension member from around the spool's annular channel144. In the figures, the upper surface of the knob170is removed so that the drive tabs174of the knob170, the axially extending teeth132of the release sleeve130, the upper surface of the spool140, and the spool's windows150are visible. As shown inFIG. 12, rotation of the knob170in the tightening direction, which is represented by Arrow A, causes the drive tab174to contact a first tooth132aof the release sleeve130and a front edge152aof the spool's window150(the first tooth132ais shown exposed inFIG. 13). Contact between the drive tab174and the first tooth132acauses the release sleeve130to rotate relative to the spool130, which causes the first tooth132ato rotate out of the window150and under the upper surface of the spool140. Rotation of the release sleeve130in this manner causes a second tooth132bto rotate into the window150on an opposite side of the drive tab174as illustrated inFIG. 12.

Contact between the drive tab174and the front edge152aof the spool's window150transfers rotational forces between the knob170and the spool140. Thus, rotation of the knob170in the tightening direction causes the spool to likewise rotate in the tightening direction, which causes the tension member to be wound about the spool's annular channel144. As illustrated, the instant embodiment includes three drive tabs174, windows150, and first teeth132a, although more or fewer of these components may be employed. In some embodiments, the release sleeve130does not include the first tooth132aand instead rotational forces are transferred to the release sleeve130via the coil spring134and tang136.

As shown inFIG. 13, rotation of the knob170in a counter direction (i.e., the loosening direction), which is illustrated by Arrow B, causes the drive tab174to counter-rotate, or rotate in an opposite direction, within the window150. This counter rotation of the drive tab174causes the drive tab to contact the second tooth132band rotate the second tooth132band release sleeve130in the loosening direction, which causes the release sleeve130to rotate the coil spring's tang136and open or widen the diameter of the coil spring134as described herein. Rotation of the drive tab174pushes the second tooth132bout of the window150and under the upper surface of the spool140until drive tab174contacts a second edge152bof the window. The first tooth132ais simultaneously rotated within the window as illustrated. In this manner the knob170is rotatable in the loosening direction to engage the release sleeve130and thereby reduce the frictional engagement of the coil spring134about the lower hub122, which allows the spool140, the upper hub126, and the coil spring134to rotate in the loosening direction and thereby reduce the tension in the tension member by unwinding the tension member from the spool's annular channel144. The tension in the tension member, and/or the drive tab174pressing on the second edge152b, may cause the spool140to rotate in the loosening direction.

Since the drive tab174is rotatable within the window150between the first edge152aand the second edge152g, the knob170will rotate by some amount relative to the spool140before engaging with the spool140and causing the spool140to rotate in the tightening or loosening direction. In some embodiments the knob170may rotate between 3 and 20 degrees relative to the spool140before engaging the spool, although a rotation of between 5 and 10 degrees is more common. The relative rotation of the knob170about the spool140is important to ensure that the drive tab174contacts the second tooth132bbefore contacting the second edge152b. This allows the release sleeve130to rotate relative to the spool140and to rotated relative to the upper and lower hubs,126and122, which opens the coil spring134and reduces the frictional engagement of the coil spring134and lower hub122as previously described.

If the drive tab174simultaneously, or nearly simultaneously, contacts the second tooth132band the second edge152b, the coil spring134may not open sufficiently and will remain frictionally engaged with the lower hub122. This frictional engagement of the coil spring134and lower hub122may require the user to exert substantial force to loosen the tension member and/or may provide a feeling that the system is locked, jammed, or otherwise faulty. Accordingly, maintaining a proper orientation of the release sleeve's teeth,132aand132b, in relation to the window150and drive tabs174is highly desired in order to provide a more consistent and comfortable user experience. The above described approach of fixing the coil spring134to the upper hub126and directly inserting the tang136into the release sleeve130help ensure that the proper orientation of the upper hub126, the coil spring134, the release sleeve130, and the spool140is maintained, which provides a more uniform and consistent feel and operation of the reel system100.

Referring briefly toFIGS. 26-30, illustrated is an alternative embodiment of a friction based load holding mechanism that includes a single hub180that frictionally engages with a coil spring182. The hub180and coil spring182are configured to be coaxially aligned and positioned within the opening or channel142of the spool140. The hub180includes axially extending teeth124that fixedly secures the hub180to the housing102. The coil spring182includes a U-shaped tang184that is configured to couple with a spool140by being positioned within a channel141of a bottom end of the spool140as illustrated inFIG. 30. The U-shaped tang184eliminates the need for the upper end of the hub180to include axially extending teeth that engage with the spool140, which design may be employed in the upper hub126described herein. The tang184may also have a shape other than the U-shape illustrated inFIGS. 26-30. The spool140is fixedly secured to the housing102via engagement of the axially extending teeth124of the hub180and the tang184of the hub180.

FIG. 27illustrates the coil spring182wound about an exterior surface of the single hub180. As described herein, the coil spring182is designed to constrict about the hub180and thereby frictionally engage with the hub180to prevent unwanted rotation of the spool140within the housing102. The frictional engagement of the coil spring182and the hub180provides the load holding property or function of the friction based load holding mechanism. Specifically, the constriction of the coil spring182about the hub180locks or secures the spring182about the hub180, which locks or secures the spool140in position relative to the housing102since the spool140is secured to the hub180. Thus, unwanted rotation of the spool140within the housing102is prevented.

The knob170, spool140, and coil spring182are designed so that when the knob170is rotated in the tightening direction (e.g., Arrow A inFIG. 12), the spool140and coil spring182are able to rotate about the hub180, which is fixed in positon about the housing102. To able rotation of the spool140and coil spring182about the hub180, the knob170includes axially extending projections,171and175, that are positioned within corresponding recesses,143and145, of the spool140. The axially extending projections,171and175, contact and engage with the corresponding recesses,143and145, of the spool140to transfer rotational forces that are imposed on the knob170from the user. The rotational forces140cause the spool140to rotate about the hub180. The coil spring182is able to rotate about the hub180due to the coupling of the U-shaped tang184with the spool140. Specifically, as the spool140rotates in the tightening direction, the rotation of the spool140transfers a rotational force to the U-shaped tang184, which widens a diameter of the coil spring182and reduces the frictional engagement of the coil spring184and hub180to the point that rotation of the coil spring182about the hub180is enabled. Ceasing the rotation of the knob170in the tightening direction causes the coil spring182to immediately reengage with the hub180, which locks or secures the spool140in position relative to the housing102.

The knob170, spool140, and coil spring182are designed so that when the knob170is rotated in the loosening direction (e.g., Arrow B inFIG. 13), the spool140and coil spring182are also able to rotate about the hub180, which is fixed in positon about the housing102. The knob includes a release protrusion179that is configured to contact and engage with an upper tang186of the coil spring182when the knob170is rotated in the loosening direction. Engagement of the release protrusion179and upper tang186transfers a rotational force to the upper tang186, which widens the diameter of the coil spring182and reduces the frictional engagement of the coil spring182and hub180to the point that rotation of the coil spring182about the hub180is enabled. Since the frictional engagement of the coil spring182and hub180is reduced, the tension in the tension member, and/or the rotation forces imposed on the knob170, causes the spool140to rotate in the loosening direction. Ceasing the rotation of the knob170in the loosening direction causes the coil spring182to immediately reengage with the hub180, which locks or secures the spool140in position relative to the housing102.

A method of assembly an article with a reel based tensioning device may include providing a reel based tensioning device, in which the reel based tensioning device includes a housing, a spool rotatably positioned within the housing, a knob member that is operably coupled with the spool to cause the spool to rotate within the housing, and a load holding mechanism that includes a spring that frictionally engages with a cylindrical member to prevent unwanted rotation of the spool within the housing. The knob member may be operationally coupled with the load holding mechanism so that a first operation of the knob member reduces the frictional engagement of the spring and cylindrical member to allow rotation of the spool within the housing to wind a tension member about the spool and so that a second operation of the knob member also reduces the frictional engagement of the spring and cylindrical member to allow rotation of the spool within the housing to unwind the tension member from about the spool. The method may also include coupling the reel based tensioning device member with the article.

The spring may be a coil spring that is wound about an exterior of a cylindrical hub member, in which the coil spring frictionally engages with the hub member by constricting about an outer surface of the hub member. In some embodiments, the hub member may include an upper hub member that is fixedly secured to the spool and a lower hub member that is fixedly secured to the housing. The upper hub member may have a diameter that is slightly larger than a diameter of the lower hub member and a distal end of the upper hub member that interfaces with the lower hub member may be tapered. Alternatively or additionally, the hub member may be an inner hub member and the reel based tensioning device may also include an outer hub member that is disposed over the inner hub member and that is operationally coupled with the knob member and the spring so that rotation of the knob member in a loosening direction reduces the frictional engagement of the spring and the inner hub member. The outer hub member may be coupled with the knob member so that rotation of the knob member in the loosening direction effects a rotation of the outer hub in the loosening direction. The spring may include a tang that is coupled with the outer hub member so that rotation of the outer hub member in the loosening direction effects a widening of a diameter of the spring, thereby reducing the frictional engagement of the spring and the inner hub member. In other embodiments, the cylindrical member may include a cylindrical channel or recess and the spring may be a coil spring that is biased radially outward into frictional engagement with an interior wall of the cylindrical channel or recess.

The friction based load holding mechanism120is typically a silent mechanism, which means that the friction based load holding mechanism120produces essentially no audible sound or minimizes the amount of audible noise that is produced. The description of nondetectable/undetectable audible noise as used herein refers to any noise level below those outlined in MIL-STD-1474D, Req. 2, pgs. 20-32, the entire disclosure of which is incorporated by reference herein. In some instances it may be desirable to provide audible feedback about the use of the reel system100. To provide the audible feedback, the reel system100may include a separate audible mechanism, such as a pawl system that produces an audible click when the reel system100is operated.FIG. 14illustrates an assembly of the components of the system that may be used to produce an audible click andFIG. 4illustrates a pawl member160of the audible mechanism. The pawl member160includes an elongate body, a first end162, and a second end164. The first end162is configured to couple with the upper surface of the spool140while the second end164is configured to interact with teeth112that are positioned on the interior region116of the housing102.

As illustrated inFIG. 14, the first end162of the pawl member160is positioned within a coupling slot or recess156of the spool140. In the instant embodiment, the first end162of the pawl member160is bent to form a loop that fits within the slot or recess156of the spool140, although other methods of attaching the first end162of the pawl member to the spool may be employed. When positioned within the housing102, the pawl member160flexes and bends between the first end162and the second end164. The elongate body of the pawl member160is positioned radially outward of a central portion159of the spool140and is flexed around the central portion159. In some embodiments, the pawl member160may be positioned radially inward of an outer protrusion157of the spool140. The outer protrusion157may hold the pawl member160in place during assembly of the reel system100and/or affect the flexibility of the pawl member160in order to produce a desired audible sound.

The second end164of the pawl member160contacts the inner surface and teeth112of the housing102. The second end164may be shaped so that the second end164easily slides about the inner surface of the housing102and is deflected into and out of the teeth112. In one embodiment, the second end164of the pawl member has a U-shaped configuration, which allows the second end164to easily slide about the inner surface of the housing and minimizes engagement of the second end164of the pawl member102and the teeth112that would impeded or hinder such movement. Unlike conventional pawls, the second end164of the pawl member160is not designed to restrict or appreciably resist rotation of the spool140within the housing102.

As the spool140is rotated in either the tightening or loosening direction within the housing102, the second end164is deflected into and out of adjacent teeth112of the housing102. The second end164produces an audible click noise as the second end164springs or bounces into engagement with each of the teeth112of the housing102. As the spool140is rotated in one direction, the pawl member160is tensioned and the second end164is pulled into and out of each tooth112of the housing102. As the spool140is rotated in the opposite direction, the pawl member160is compressed and the second end164is pushed into and out of each tooth112. In this manner, an audible click sensation is produced as the reel system100is operated to both tension and loosen the tension member.

The second end164of the pawl member160may be configured to produce an essentially uniform sound regardless of the direction of rotation of the spool, or may be configured to produce a different sound for when the spool140is rotated in the tightening direction versus the loosening direction. For example, the second end164may be configured to respond slightly differently when pulled into engagement with each tooth112versus when it is pushed into engagement with each tooth, which may produce a different audible sound. The sound may also be adjusted by selecting the thickness of the pawl member160, the length of the pawl member160, and/or the number of teeth that are employed in the system. In some embodiments, the spool140may include between about 20 and 40 teeth, and more commonly between about 25 and 35 teeth. In a specific embodiment, the spool140may include 32 teeth. The reel system100could also implement multiple pawl members (e.g., two or more) with each pawl member being employed during the tensioning or loosening of the tension member. In other embodiments, the audible mechanism could include detents that engage to produce an audible sound or a linear pawl beam that interacts with spline teeth.

A method of configuring a reel based tensioning device may include providing a reel based tensioning device, in which the reel based tensioning device includes a housing, a spool that is rotatably positioned within the housing, a knob member that is operably coupled with the spool to cause the spool to rotate in a first direction within the housing to wind a tension member about the spool, and a load holding mechanism that is coupled with the spool and that is configured to allow rotation of the spool in the first direction within the housing and to prevent rotation of the spool in a second direction within the housing to prevent unwinding of the tension member from about the spool.

The method may also include coupling an audible component with the reel based tensioning device in which the audible component is configured to produce an audible noise responsive to operation of the knob member to signal an adjustment of the tension member. The method may also include adjusting the audible component to adjust the audible noise that is produced by the audible component.

The load holding mechanism may not produce an audible noise that is detectable by a human ear. The audible component may be configured to produce an audible noise responsive to tensioning of the tension member and to produce an audible noise responsive to loosening of the tension member. The audible noise that is produced responsive to tensioning of the tension member may be different than the audible noise responsive to loosening of the tension member. The audible component may include a pawl member or beam that engages with the housing to produce the audible noise. The pawl member or beam may be incapable of preventing rotation of the spool within the housing when an appreciable rotational force is imposed on the spool via the tension member or knob member. The load holding mechanism of the reel base tensioning device may not include a pawl member or beam.

In some instances, it may be beneficial to form a component of the reel system100directly onto a fabric material so that the fabric is integrally formed with or integrated within the component. In some embodiments the fabric material may facilitate in attaching the component with an article, such as attaching the component to a shoe. In a specific embodiment, the component may be formed onto the fabric material via insert molding in which the fabric material is positioned within a mold or die and a polymer material is injected atop or through the fabric material. The component of the reel system may be a first component that includes a top end, a bottom end, and an interior cavity within which a second component of the reel based tensioning system is positionable. A specific example of a first component is a base member or bayonet that is configured to couple with a housing of the reel system. Another example of a first component is a housing that is configured to couple with a spool and other components of the system as described herein. Yet another example of a first component is a guide member that includes an interior cavity that is configured to receive a tension member of the reel system in order to guide the tension member about a path of an article.

When the component is formed onto the fabric material, the fabric material may be positioned near the bottom end of the component and may extend laterally from at least a portion of an outer periphery of the component, and more commonly around the entire periphery of the component. The fabric material may be integrally coupled with the first component by injecting the polymer material (i.e., thermoplastic or thermoset material) of the component through the fabric material so that the polymer material of at least a portion of the component is saturated or impregnated through the fabric material with the polymer material extending axially bellow a bottom surface of the fabric material and axially above a top surface of the fabric material. In some embodiments the polymer material may be saturated or impregnated through the fabric material so that an entire bottom end of the component extends axially bellow the bottom surface of the fabric material and axially above the top surface of the fabric material. In such embodiments, the polymer material of the component's bottom end may form an annular ring on the bottom surface of the fabric material. In other embodiments only a portion of the bottom end may extend axially above and below the fabric material with the remaining portion of the bottom end positioned only on one side of the fabric material.

Referring now toFIGS. 15, 17-19, and 23-25illustrated is the base member220attached to a piece of woven material, such as fabric200. The fabric may be essentially any fabric, such as a polymer based fabric. In a specific embodiment, the fabric may be a500denier polyester fabric.FIG. 17illustrates the base member220unattached from the fabric200whileFIG. 18illustrates a perspective view of the base member220attached to the fabric200. As illustrated inFIG. 18, the fabric200is substantially flush with a bottom surface of the base member220after the base member220is attached to the fabric200. The fabric200extends laterally from at least a portion of an outer periphery of the base member220and more commonly around an entire periphery of the base member220.FIG. 15andFIG. 24illustrate bottom views of the fabric200and base member220showing alternative attachment configurations of the base member220and fabric200.FIG. 23illustrates a bottom view of an embodiment of the fabric200prior to forming the base member220onto the fabric200.FIG. 19illustrates a cross sectional view of an embodiment of an attached base member220and fabric200.

In an exemplary embodiment, the base member220is directly injected onto the fabric200. This is achieved by insert molding or injecting the material of the base member220through a bottom surface of the fabric200, which results in a significantly high adhesion strength and prevents or minimizes separation of the base member220from the fabric200. For example, direct injection of the base member's material through the bottom surface of the fabric200may enable the materials to experience a50Kg force before beginning to separate. The material of the base member220is commonly a polymer material (i.e., thermoplastic or thermoset material), which is injected through the fabric200so that when the base member220is formed, the fabric200is disposed within at least a portion of the base member220so that the polymer material is disposed on opposite sides of the fabric200. The positioning of the fabric200within the base member220is shown inFIGS. 15, 19, and 24.

As illustrated inFIG. 17, the base member220may be a component of the system that includes an interior cavity that is configured to receive and releasably couple with a housing102as shown inFIG. 16. In other embodiments, the base member may be a housing component, such as the one illustrated inFIG. 16, which may be directly injected onto, and integrally formed with, the fabric200. In such embodiments, the need for a separate base member220and housing102may be eliminated and these components may be integrated into a single component that is integrally coupled with the fabric200. The housing component may include lace ports104through which a tension member or lace is disposed.

In some instances, the material of the base member may be injected into the fabric200so that the saturation or integration of the material within the fabric200is varied. The term saturation or integration of the base member's material within the fabric200refers to the amount of the base member's material that remains disposed within the interior of the fabric200after the injection process. When the base member's material is highly saturated/integrated within the fabric200, the injected base member material is essentially positioned on both sides of the fabric200and through the interior of the fabric. When the base member's material is less saturated/integrated within the fabric200, the injected base member material does not fully penetrate through the fabric200or is essentially positioned on one side of the fabric200. The fabric is more readily visible in areas where the base member's material is less saturated/integrated within the fabric200. In a specific embodiment, the base member's material is glass filled polypropylene and/or co-polyester.

In one embodiment, the saturation/integration of the base member's material may vary from between segments or portions of the base member so that the base member's material is highly saturated/integrated through the fabric200in one segment or portion of the base member and less saturated/integrated through the fabric200in another segment or portion of the base member. In such an embodiment, the variance of the base member's material within the fabric200is illustrated by the cross hatching or shaded areas ofFIGS. 15 and 19. The cross hatching or shaded areas represent portions of the fabric200where the base member's material is more saturated or integrated into the fabric200. These areas may appear darker or of a slightly different color due to the base member's material being more concentrated in these areas and more visible from a bottom surface of the fabric200. The variance of the saturation/integration of the base member's material may be designed to provide a desired property, such as increased bond or adhesion strength between the two materials, increased strength of the base member, etc.

The strength of the bond or adhesion between the fabric200and base member220may be substantially increased when the base member's material is highly saturated/integrated within the fabric200. However, the strength of the base member220itself may be decreased when the base member's material is highly saturated/integrated within the fabric200due to less material being present within the base member. The decreased strength of the base member220may negatively affect how the base member220interacts with other components of the system, such as the housing102. For example, a wall224that is opposite the front tab222may be a thinner section of material in order to reduce the size and/or weight of the base member220. If the base member220is too thin near the wall224, the wall224may crack or break from the pressure or force that is exerted on the wall224by the housing102. As such, it may be desirable to construct the base member220and fabric200so that the wall224remains relatively strong and reinforced while an increased bond/adhesion between these materials is achieved due to saturation of the base member's material within the fabric200.

In some instances, the base member220may experience greater external forces near the front tab222. The external force may urge or cause the base member220to peel away from the fabric200and thus, an increased bond/adhesion strength near the front tab222may be desired. The wall224may be used primarily to couple the base member220with the housing102and thus, it may be more desirable to reinforce or strength the base member220adjacent the wall224. This increased bond/adhesion strength near the front tab222and the increased reinforcement of the base member220near the wall224may be achieved by increasing the saturation/integration of the base member's material near the front tab222while decreasing the saturation/integration of the base member's material near the wall224as shown inFIGS. 15 and 19.

In one embodiment, the amount of saturation/integration of the base member's material within the fabric200may be controlled based on the arrangement of injection holes226that inject the base member's material through the fabric200. The base member's material may more fully saturate/integrate into the fabric200around the injection holes226and thus, the injection holes226may be positioned adjacent areas of the base member220where an increased bond/adhesion strength is desired and may not be positioned in areas where increased component strength is desired.FIGS. 15 and 19illustrate the injection holes226positioned near the front tab222where the cross-hatching or shading is illustrated and where increased saturation/integration of base member's material and fabric200is typically desired. In this manner, the hole pattern may be engineered to provide a designed combination of desired strength without compromising the integrity of the component.

In another embodiment, the saturation/integration of the base member's material may be relatively uniform relative to the base member so that the base member's material is either highly saturated/integrated through the fabric200or slightly saturated/integrated through the fabric200.FIG. 24illustrates a bottom view of the fabric200that shows a uniform saturate/integration of the polymer material through the fabric. InFIG. 24, the base member's material is highly saturated/integrated through the fabric200, which results in the fabric200being disposed within the polymer material of essentially an entire bottom end of the base member220. The description of the fabric200being disposed within the polymer material of the base member220means that the polymer material is disposed or positioned on opposite sides of the fabric200. Since the base member220has an essentially cylindrical configuration as shown inFIG. 17(i.e., a circular bottom end and hollow interior), the positioning of the polymer material on opposite sides of the fabric200results in the formation of an annular ring223on a bottom surface of the fabric200as illustrated inFIG. 24. When the bottom end of the base member220has a different configuration (e.g., planar surface, oval shave, etc.), the shape that is formed on the bottom surface of the fabric200would correspond to the shape of the bottom end of the base member220.

As shown inFIG. 25, in some embodiments the base member220includes one or more thinner material sections225. Since the fabric200is disposed or positioned within the base member's material, the fabric200may be visible on a top surface of the thinner material sections225of the base member220.FIG. 23illustrates a view of the fabric200before the base member's material has been injected through the fabric200. The fabric200includes injection holes226that are arranged to facilitate in saturation/integration of the polymer material through the fabric200to form the annular ring223illustrated inFIG. 24.FIG. 23also illustrates the fabric200includes a plurality of tabs240that extend laterally outward from a main body of the fabric200. One or more of the tabs240may include an aperture241as illustrated.

While the variance of the material saturation/integration within the fabric200is shown in relation to the base member220, it should be realized that other components of the system may likewise be directly injected onto a fabric, such as a guide member for the tension member and other components. Thus, the general description above is related to any reel system component and not specifically to base members.

A method of forming a component of a reel based tensioning system may include providing a fabric material and positioning the fabric material within a die or mold. The method may also include injecting a polymer material through the fabric material so that the polymer material fills a void or space within the die or mold that defines a shape of a first component of the reel based tensioning system. The method may also include cooling the polymer material so that the polymer material hardens and forms the first component of the reel based tensioning system. The polymer material of at least a portion of the first component is saturate or impregnate through the fabric material so that the polymer material of the first component extends axially bellow a bottom surface of the fabric material and axially above a top surface of the fabric material. The fabric material may be positioned within a bottom end of the die or mold so that the polymer material is injected through the fabric material from the bottom end of the die or mold toward a top end of the die or mold. The bottom end of the die or mold may correspond to a bottom end of the first component. The polymer material may be injected through the fabric material and cooled so that the polymer material of an entire bottom end of the first component is saturated or impregnated through the fabric material. In such instances, the polymer material of the entire bottom may extend axially bellow the bottom surface of the fabric material and axially above the top surface of the fabric material. The polymer material may be injected through the fabric material and cooled so that the polymer material forms an annular ring atop the bottom surface of the fabric material. The polymer material may comprise or consists of a glass filled polypropylene material, a co-polyester material, or a combination thereof. The polymer material may be injected through the fabric material and cooled so that the polymer material is visible from a top surface of a materially thinner section or segment of the first component.

Referring now toFIG. 20, illustrated is a stop cord or mechanism230that is attached to the spool140and the housing102. The stop cord230is wound around a stop cord channel232that is separate from the annular channel144. The stop cord230is wrapped around the stop cord channel232so that as the tension member is unwound from the annular channel144, the stop cord230wraps around the stop cord channel232. The length and arrangement of the stop cord230and the stop cord channel232is such that when the tension member is fully or mostly unwound from the annular channel144, the stop cord230is mostly or fully wrapped around the stop cord channel232, which prevents further rotation of the spool140within the interior region116of the housing102. In this manner, the stop cord230prevents back-winding of the tension member about the annular channel144—i.e., winding of the tension member around the annular channel144when the spool is rotated in the loosening direction. The function and arrangement of the stop cord is further described in U.S. Pat. No. 9,259,056, filed Jun. 21, 2013, and entitled “Reel Based Lacing System,” the entire disclosure of which is incorporated by reference herein.

To attach the stop cord230to the reel system100, a proximal end of the stop cord230is inserted through a coupling aperture108in the housing and a knot is tied in the proximal end of the stop cord230. The knot engages with the coupling aperture108to prevent the proximal end of the stop cord230from being pulled through the coupling aperture108. A distal end of the stop cord230is similarly inserted through a pair of apertures (not shown) in the spool140and a knot is tied in the distal end of the stop cord230. The knot engages with an uppermost aperture (not shown) to prevent the distal end of the stop cord230from being pulled through the spool140. When the knot in the distal end of the stop cord230is engaged with the spool's aperture, the knot is positioned within a slot109of the spool140. In some instances, a small portion of the stop cord230extends across the spool's annular channel144. In such instances, the tension member (not shown) is wound around the stop cord230.

FIGS. 21-22illustrate an alternative embodiment of a coil spring400and release hub assembly. Specifically, the coil spring400is configured to be positioned within an upper hub326and a lower hub322. An outer diameter of the coil spring400is approximately the same size as or slightly larger than an inner diameter of the upper hub326and lower hub322so that the spring400flexes outward into frictional engagement with the upper hub326and the lower hub322in order to lock the two hubs together in a manner similar to that described herein. As shown inFIG. 22, the lower hub322is fixedly secured to the housing of the reel system500via axially extending teeth324while the upper hub326is fixed to the spool of the reel system500via axially extending teeth328. Locking the upper hub326and the lower hub322together prevents the upper hub326from rotating relative to the lower hub322, which locks the spool in position relative to the housing.

To unlock the upper hub326from the lower hub322, the diameter of the coil spring400is reduced. The coil spring400includes a tang402that extends radially inward and that engages a release sleeve (not shown) or a component of the knob. As the knob is rotated in a loosening direction, the tang402is engaged, via the release sleeve or a component of the knob, which causes the spring coil400to be wound in a direction that causes the coil spring to constrict or move radially inward thereby (i.e., a counter-clockwise direction for the spring shown inFIG. 21). Movement of the coil spring400in this manner causes the coil spring's outer diameter to decrease to the point where the upper hub326is unlocked from the lower hub322and is able to rotated relative to the lower hub322, which allows the spool to rotate within the housing in the loosening direction.

The upper hub326and lower hub322may have different sized inner diameters, may be made of different materials, and/or may have different surface finishes to ensure that the coil spring400is rotatable about one of the hubs while remaining fixed to the other hub as desired. When a release sleeve is employed, the release sleeve may be a cylindrical sleeve that fits entirely within the interior of the coil spring400in a manner that minimizes frictional engagement of the release sleeve and coil spring400. In addition, although the tang402is shown positioned near the outer end of the upper hub326, in other embodiments the tang402may be positioned adjacent an outer end of the lower hub322.

While several embodiments and arrangements of various components are described herein, it should be understood that the various components and/or combination of components described in the various embodiments may be modified, rearranged, changed, adjusted, and the like. For example, the arrangement of components in any of the described embodiments may be adjusted or rearranged and/or the various described components may be employed in any of the embodiments in which they are not currently described or employed. As such, it should be realized that the various embodiments are not limited to the specific arrangement and/or component structures described herein.

In addition, it is to be understood that any workable combination of the features and elements disclosed herein is also considered to be disclosed. Additionally, any time a feature is not discussed with regard in an embodiment in this disclosure, a person of skill in the art is hereby put on notice that some embodiments of the invention may implicitly and specifically exclude such features, thereby providing support for negative claim limitations.

As used herein and in the appended claims, the singular forms “a”, “an”, and “the” include plural referents unless the context clearly dictates otherwise. Thus, for example, reference to “a process” includes a plurality of such processes and reference to “the device” includes reference to one or more devices and equivalents thereof known to those skilled in the art, and so forth.