Tool operated adjustment devices, fit systems, and line tensioning systems

A tool-operated adjustment device includes a housing supporting a rotatable spool that is operably coupled to a tension line. The spool is configured to rotate about a first axis in a first direction to wind the tension line, and to rotate in a second direction opposite the first direction to unwind the tension line. The device includes a socket pivotally coupled to the housing and configured to rotate about a second axis. The socket is selectively coupled to the spool to drive rotation of the spool in the first direction. The socket is configured to removably connect and disconnect to a tool configured to rotate the socket about the second axis. The device includes a release mechanism that is configured to selectively release the spool such that the spool is free to rotate in either the first or second direction in response to manual forces applied to the release mechanism.

BACKGROUND

The present disclosure relates to low profile adjustment devices for use with various for articles, fit system, and line tensioning systems.

2. State of the Art

How well a wearable article or device fits the body is highly important in the daily function of humans or even for animals. For example, wearable articles and devices can include, by way of example, garments, shoes, backpacks, sporting gear, wearable protective devices, sporting braces, orthosis, and/or prosthesis. Several factors can be weighed in how appropriate or satisfactory a wearable article or device fits the body, including whether the fit system transmits satisfactory load, provides satisfactory stability, suspends on the body, provides efficient congruency of the article or device during motion, provides sufficient mobility, is easily fitted, and/or is comfortable. These factors can be considered determinates in how appropriate or effective the fit of the article or device is on the body and they are directly related to how the article or device is secured or fastened to the body. Generally, the wearable articles or devices are secured to the body by tightening around the body. The mechanisms and associated methods of how articles or devices are secured to the body are hereby referred to as fit systems.

Fit systems and related devices and methods generally are operably attached to one or more flexible elongate members or tension lines (such as straps, cables, laces, etc.) with one or more attachment points or interfaces to the article or device. The attachment points or interfaces may decrease in distance relative to one another or relative to the fit system, which can be referred to as contraction or shortening. Such contraction can involve decreasing the effective length of the flexible elongate member(s) of the fit system and possibly increasing the amount of tension (or tensile loading) experienced by the flexible elongate member(s) of the fit system. Such contraction can occur when tightening or closing or other movement of the article or device with respect to the body. Alternatively, the attachment points or interfaces may increase in distance relative to one another or relative to the fit system, which can be referred to as extension or lengthening. Such extension can involve increasing the effective length of the flexible elongate member(s) of the fit system and possibly deceasing the amount of tension (or tensile loading) experienced by the flexible elongate member(s) of the fit system. Such extension can occur when loosening or other movement of the article or device with respect to the body.

The determinates of the appropriateness and effectiveness of a fit system may be associated with design elements of the fit system including: the mechanisms and associated methods for contraction and extension, the inherent mechanical advantage of a given fit system, mechanical reliability of the overall system and toughness of individual components, maximum load and tension, distance between the attachment points or interfaces in the maximum contracted and maximum extended positions, profile height of the fit system, width and length of the fit system, rigidity of the fit system and its components, whether the contraction and extension is incremental or analog in nature, how smooth or abrupt is the contraction and extension, attachment requirements of the fit system, system weight and suspension forces provided by the fit system, and pressure distribution of the fit system.

The mechanism/s and associated methods of use weigh heavily on the user experience of the fit system and is the driving factor for many of the other determinates of the fit system. For example, a mechanism may be mechanically effective but may have poor ergonomics. The mechanism may also affect the speed and direction of the contraction and extension. For example, the gear ratio mechanism within a fit system may provide high mechanical advantage, but a slow speed of contraction, which may be ideal for some applications and too slow for others. In another applications, the speeds of contraction and extension may be key for some applications. For example, certain military applications such as a fit system for a military aid pack or backpack may need to have a high speed of contraction and very high speed of extension such that the operator can quickly remove the pack if they need to quickly become mobile to avoid harm. In this application, a high mechanical advantage for contraction or extension may be less important because most users would have a relatively high level of strength. In still other applications, the direction of pull of the contraction or extension may be important. For example, contracting in a single direction could cause misalignment of a knee joint in an orthosis as the user tightens the brace onto their body. In these cases, a balanced, dual direction fit system would be more appropriate. How easily a fit system performs contraction and extension is paramount in its ability to deliver optimal fit and user experience. Many users of orthopedic devices have compromised strength and/or dexterity so mechanisms and methods that make the fit system easy for them to contract to the desired amount and easily extend for release is a huge need and large benefit. Conversely, if a fit system is so easily engaged for contraction or extension that it is accidentally triggered, that can be a serious functional problem as well. Mechanism and methods drive other factors such as the inherent mechanical advantage of the system and the increments of tightening. Some applications may require small increments of contraction or extension whereas others may be optimized by larger and therefore faster increments of change.

In addition, some mechanisms and methods of fit systems may allow for an opening or separation between attachment points or interfaces whereas others may be better suited or even require the fit system to remain as a single unit between attachment points or interfaces. Some applications may require that a fit system opens up in order to don and doff the device while others may not. For example, a leg brace may require that users open up the device in order to place their leg into the device whereas protective pants for motorcycle riders may allow for a waist fit system stay in one piece and loosen only while they pull it up to their waist.

The inherent mechanical advantage of a fit system is a byproduct of the mechanisms and the methods associated with the fit system. Such fit system can provide a quantifiable mechanical advantage ratio which is the amount of output force over the amount of input force. The speed or time needed to contract or extend the fit system a given distance is usually inversely correlated with mechanical advantage such that when mechanical advantage is high, speed is low and vice versa. Many applications differ in the mechanical advantage requirement, but most applications have a specific ratio or range of ratios that is optimal for function. If the mechanical advantage is too high or more than required for a given application, it may unnecessarily sacrifice speed. Mechanical advantage within a fit system directly relates to the maximum tension and load of the system. The maximum tension and load of a fit system is described in detail below.

The mechanical reliability and toughness of the fit system relates to the materials utilized by parts therein, geometry, dimensions, and manufacturing methods. Specifically, the overall fit system may only be as strong as its weakest link. Some parts can fail and cause catastrophic failure while others may not. Failure of some fit systems could lead to the users getting trapped or stuck in their device or with their device. In other situations, the user may be highly dependent on the device. Failure of a fit system could potentially even contribute to a fatal accident. Reliability is therefore extremely important especially in certain circumstances and applications.

Maximum tension of a fit system is typically dependent on the maximum tensile loading of the flexible elongate member(s) of the fit system. In many applications, the maximum tensile loading relates directly to the maximum input force multiplied by the mechanical advantage. The input force is most often the manual force of the user but may be the force imposed by another person or an electronic or other automated system. The input force is transferred to the fit system members via the mechanisms within the fit system which may or may not include mechanical advantage. The tensile loading of the flexible elongate member(s) of the fit system can transfer load or force onto the user's body. Generally, the load is directed into the body or, in other words, towards the center of the body's long axis or the long axis of a limb but may also be slightly oblique to the direction directly towards the long axis. If such loading forces are directed in an angle that is too oblique to the long axis they will likely cause the device to shift proximally or distally on the body unless counterbalanced by a geometric feature of the body or other feature. The amount of load transferred onto the body can also related to other factors. For example, the amount of body exposure from the device seen by the fit system will affect the how much of the tension force is transferred directly onto the body or into the device.

The loading directed into the body can apply pressure to the body. Generally, the pressure distribution applied to the body is dependent on the amount of loading applied by the fit system to the body divided by the surface area of the applied loading. Pressure distribution of the fit system is explained in further detail below. In many cases, the fit system can transfer some tension forces onto the device (for example, by the device changing shape or reducing in volume), thereby reducing load applied to the body. The amount of desired load or optimal load delivered onto the body by the fit system may differ per application, as the body changes, during activity changes, within certain movements, in certain positions, and/or over time. Although the optimal loads may vary per application and other variables, optimal performance is generally seen within a definitive range. The humans and animals generally prefer a similar range of load and associated pressure onto the body and within specific segments of the body. Beyond the level of preference, loads and pressures that are beyond a recommended range may cause a reduction in blood flow and/or other damage, discomfort, or pain. Conversely, if loads and pressures are too low, the device may fall down on the body or be loose on the body which may lead to damage, discomfort, or pain.

The maximum effective length of the flexible elongate members of the fit system can be referred to as the travel within a fit system. Travel within a fit system may relate to the amount of space available for a flexible elongate member to collect into the fit system or the distance of linear teeth in a ratchet ladder. The available amount of travel within a fit system may limit the amount of load that a fit system can deliver onto the body in that the maximum travel may be reached before the user gets to their desired amount of load onto the body. Travel may also directly affect device sizing in that a fit system with greater travel is likely to accommodate a wider range of body sizes and vice versa. These factors might suggest that fit systems should always include a maximum or large amount of travel. However, while increased travel may be beneficial, it often has a negative or inverse correlation on other determinates of the fit system such as the size, profile, weight, and other factors discussed below.

The profile height of the fit system is extremely important to product developers and end users. Profile height refers to the distance that the fit system protrudes away from the body or, in other words, how much it sticks out. Developers and end users have a strong preference or requirement for the fit system to have a low-profile for the aesthetic look and finish quality that they demand. Moreover, the profile height also plays a role in function and safety. If a fit system has a large profile height it will have a higher risk of catching on things or it may make it difficult or impossible to wear clothing over the fit system. Beyond these undesirable attributes, a fit system with a large profile can be a significant risk of injury due to the fact that if the user falls or bumps into something, the bulk of the fit system can be pushed into the body and can cause injury.

Similar to the profile height, the width and length of a fit system may also be important for applications of use. Width or length can limit applicability in some cases that may have a limited surface area of application. For example, shoes have a limited surface area that is acceptable for a fit system. Fit systems may be limited in their applicability to shoes if their width or length is over 45 mm or even 35 mm in some cases. However, beyond surface area limitations, larger width and length are far more acceptable for most applications fitting the body as compared to profile height.

In some cases, fit requirements can be very specific and a distance of one millimeter can be the difference in too loose and just right. In these cases, an analog fit system that can adjust in a continuous and controlled manor may be ideal. In other applications, incremental tightening provides the appropriate amount of fidelity while enabling for a wider array of fit system mechanisms. Incremental systems are often faster than analog systems that provide a control at a micro level. All incremental systems are not created equal. Some incremental fit system may offer small increments like 1.5 millimeters whereas others may offer large steps of 6 millimeters. Requirements for the distance between increments are specific per application but in general the range is between 0.5 mm and 8 mm. Regardless of whether a system is incremental or analog, the mechanism or method of use may provide a smooth transition as it is used to adjust fit or it may provide an abrupt experience. In general, the experience is understandably more favorable if it is more controlled and smooth. However, some cases require fast release or removal of a device.

Various fit systems have been proposed. An example of one such device is described in U.S. Pat. No. 9,867,430 (Boa Technologies). This prior art stacks fit system mechanisms and members vertically and thereby has a large profile height. The profile height of the high mechanical advantage (approximately 6 to 1 mechanical advantage) version of the commercial embodiment of this technology is approximately 33 mm high. The profile height of the mid-power mechanical advantage (approximately 2 to 1 mechanical advantage) of the commercial embodiment of this technology is approximately 23 mm high. The profile heights for this technology are excessive for many applications. This commercial technology is also limited in mechanical reliability. The system utilizes cables or laces that are approximately 0.8 to 1.0 mm thick and can fail during use of many applications. Additionally, release is abrupt and may be shocking and jarring to the user. Moreover, users with poor hand dexterity lack the capacity to wind or release the tension line of the fit system.

Ratchet ladders have sufficient mechanical advantage for many applications, but the ladder strap teeth often cannot accommodate angles greater than 30 degrees without skipping. Additionally, release is abrupt and may be shocking and jarring to the user. Also, these systems are generally between 25 mm and 45 mm and are thereby excessively bulky in profile for many applications.

Ratchet straps offer large mechanical advantage and high mechanical reliability, however their profile height, difficulty and abruptness in releasing mechanisms, and challenge of donning wherein one needs to feed a strap through a split axis and hold the strap in tension in order to start it: all make for these systems to be inapplicable as a fit system.

Over-center cam buckles serve as fit systems for ski boots and other similar products. These fit systems and other similar products effectively provide mechanical advantage when they are attached to rigid plastic structures on both sides but they do not include fastening mechanism that allow them to mount to a strap and the base of the over-center cam would create high peak pressures if it were used on a loose strap due to its small base of support. The catch mechanisms for these devices are also not designed to work with a loose strap and create difficult ergonomics if they are used with loose straps. Moreover, these systems offer no security latch mechanisms to maintain the strap in the closed position, do not offer macro tightening and loosening, and are highly dependent on the specific geometry (angles and contours) of the application. All of these factors amount to over-center systems not being applicable to products fitting the body with the exception of products that include hard plastic rigid shells like ski boots.

Webbing straps with hook and loop fasteners (sold under the tradename VELCRO) is often used as a fit system in almost all devices that fit the body ranging from shoes to neck braces. The ubiquitous use of hook and loop systems may relate to its low cost, accessibility, low-profile, and ease in integration into product development; all fit system factors that affect a company's motivation to integrate a fit system into their product beyond the end user attributes discussed in detail above. Buckles, fasteners, and chafes are often utilized in combination with hook and loop fasteners in order to add some mechanical advantage and/or provide greater ease of use. Although hook and loop fasteners are widely used, end users often complain of the noise it makes during removal, how it often attaches to unintended materials and surfaces, how it collects lint, how it is difficult to tighten and loosen especially for those with low strength capacity, and how it tends to wear out with prolonged cycle use.

The most common fit system utilized for shoes is traditional laces. Laces offer minimal mechanical advantage but that is all that is needed in most shoes since the dorsum of the foot offers a large surface area to suspend on. Even though the need for mechanical advantage and suspension are low, fast, and ergonomic methods to tighten and loosen shoes is still desired.

Line tensioning systems and related methods can generally include one or more flexible elongate members (such as straps, cables, wires, etc.) with one or more attachment points or interfaces to an article, device, or structure. Similar to fit systems, the attachment points or interfaces may decrease in distance relative to one another or relative to the line tensioning system, which can be referred to as contraction or shortening. Such contraction can involve decreasing the effective length of the flexible elongate member(s) of the line tensioning system and possibly increasing the amount of tension (or tensile loading) experienced by the flexible elongate member(s) of the line tensioning system. Alternatively, the attachment points or interfaces may increase in distance relative to one another or relative to the line tensioning system, which can be referred to as extension or lengthening. Such extension can involve increasing the effective length of the flexible elongate member(s) of the line tensioning system and possibly deceasing the amount of tension (or tensile loading) experienced by the flexible elongate member(s) of the line tensioning system.

The determinates of the appropriateness and effectiveness of a line tensioning system may be associated with design elements of the line tensioning system including: the mechanisms and associated methods for contraction and extension, the inherent mechanical advantage of a given line tensioning system, mechanical reliability of the overall system and toughness of individual components, maximum load and tension, distance between the attachment points or interfaces in the maximum contracted and maximum extended positions, profile height of the line tensioning system, width and length of the line tensioning system, rigidity of the line tensioning system and its components, whether the contraction and extension is incremental or analog in nature, how smooth or abrupt is the contraction and extension, attachment requirements of the line tensioning system, system weight and suspension forces provided by the line tensioning system, and pressure distribution and loading provided by the line tensioning system.

SUMMARY

In accordance with a first aspect, adjustment devices are described herein that may be useful in a variety of applications, including for wearable articles and tension systems. The adjustment devices described herein include a tool-operated mechanism that drives a spool for winding a tension line.

According to a first embodiment, a low-profile tension adjustment device is provided for winding and unwinding a flexible elongate member (i.e., a tension line cable or lace). The adjustment device may include a housing comprised of a base and a cover, and a spool surrounded and housed by the housing. The spool is rotatable relative to the housing using an adjustment tool, such as a standard and readily available hex shaped key (i.e., an “Allen wrench” or “Allen key”), ratcheting wrench, or power tool. The hex shaped key can be in the appropriate size to apply the necessary force for an application. A driving portion of the adjustment tool and a control port or socket of the adjustment device are configured for mating engagement. In an example of a tension adjustment device adapted to mate with a hex-shaped wrench, the control port includes a hexagonal port that mates with the hexagonal driving end of the tool. The control port alternatively may be provided with other non-circular shapes (besides hexagonal) by way of which a torqueable mating engagement can be made with an adjustment tool that is pushed into or otherwise inserted into the port. When the flexible elongate member is connected to the spool, the tool may be used to rotate the spool to draw the flexible elongate member into the housing and onto the spool, which may impart tension to the flexible elongate member.

Retention of flexible elongate member wound onto the spool can be controlled by a retainer (e.g., a mating hex-shaped retainer), which is biased into engagement with the control port and may be configured to be rotationally fixed with respect to the housing. For example, the base of the housing may include a post configured to be received by the retainer. In such an example, the post and the retainer may have a mating connection that prevents relative rotation between the retainer and the housing.

The control port, the spool, and the retainer may be coaxially aligned along a central longitudinal axis. The retainer may be configured for relative translation with the spool and the housing along the longitudinal axis.

In embodiments, insertion of the tool into the control port may cause the retainer to translate along the longitudinal axis against the bias of the spring, which may release the spool to permit the spool to rotate relative to the housing. Any tension in the elongate member is transmitted to the tool and the hand of the user, who is free to wind or unwind the elongate member by rotating the tool relative to the housing. The user holding the tool can feel the amount of tension they are inputting to the device. Some prior art ratcheting devices block or otherwise do not provide tactile feedback to the user.

In embodiments, snap fit indicating features (e.g., tabs) may be provided between the housing and spool which can provide auditory and haptic feedback to the user as the spool rotates relative to the housing to indicate when the retainer is aligned with the spool. When the spool and the retainer are aligned at an indicating snap fit feature, the operator can remove the tool and the retainer will seamlessly engage with the hex shaped control port. In one exemplar embodiment where the retainer and the tool port are hexagonal, there are six indicating features. Thus, in that example, the minimum increment of rotational adjustment of the spool relative to the housing is sixty (60) degrees.

The adjustment device may be configured to allow the user to choose their preferred direction of tightening and loosening. For example, the spool defines holes for receiving the elongate element. The holes are surrounded by symmetrically filleted surfaces that have a large enough radius of curvature to avoid weakening the elongate member if wound in either rotational direction. This permits the user to rotate the spool clockwise or counterclockwise to collect the elongate member.

The elongate member wound around the spool, and any tension developed in the elongate member, can be fully or partially released by rotating the spool in a second direction opposite the first direction used to wind the elongate member. Rotating the spool in the reverse direction can be accomplished by the user rotating the tool in the second direction or by the user allowing the tool spin freely as tension in the elongate member drives the tool and the spool in the reverse direction.

In embodiments, the housing may include a flange or lip with anti-rotation features, such as notches, holes, or grooves. The device may be mountable to an article by connecting the flange or lip to a mounting surface of the article. This mounting option may be useful for integrating the device into the lamination of a prosthetic socket or 3D print of a prosthetic socket. Alternatively, a receiving feature (e.g., a receiving socket) configured to receive the flange or lip, can be part of a molded or machined into a part for integration into a mass manufactured product or garment. Such receiving feature may have anti-rotation features that align or mate with the anti-rotation features of the flange or lip to prevent relative rotation between the housing of the device and the receiving feature.

In embodiments, a plurality of exit ports or holes may be defined in the base of the housing for passage of the tension line through the housing to the spool. In one embodiment, four (4) exit ports are provided spaced ninety degrees apart with respect to the longitudinal axis. The plurality of exit holes allows a user to select holes for appropriate orientation of the elongate member for the specific application. In embodiments, the exit holes may include a blind hole to receive a cable or lace housing to control routing of the cable.

In embodiments, access to the spool for assembly or replacement of the elongate member is made possible by way of the removable housing cap, which can be removed and replaced by way of an adjustment.

In another embodiment, a toothed retainer is substituted for the non-circular port. The retainer may have a plurality of teeth circumferentially spaced near or at an outer diameter of the retainer. This arrangement spaces the teeth radially outward from the control port. The retainer may be biased by a biasing member (e.g., a spring) to engage with mating concentric teeth at or near an inner diameter of the spool. This arrangement of the teeth of the spool and the retainer can reduce the area of mating surfaces of the control port and retainer required for structural engagement directly under and within the control port. As a result, one advantage of this embodiment is that the overall profile height of the housing can be less than the profile height of the housing of earlier embodiments.

Moreover, having a larger number of teeth spaced relatively closer together, can allow for smaller increments (in terms of angular adjustment) of adjustment. In one example embodiment, the retainer has 20 teeth, such that the adjustment increments are 18 degrees, allowing for a finer adjustment than an example where 6 teeth permit a 60 degree adjustment increment.

Embodiments of the adjustment device may also include a mounting flange. The housing may have an external stitching flange that may be constructed for threaded connection to a mounting surface of an article, such as softgoods (e.g., clothing and footwear).

Another embodiment of an adjustment device may include one or more features of embodiments described hereinabove and may also include a ratcheting mechanism to maintain tension in the elongate member during and after collection of the elongate member. The ratcheting mechanism may include a one-way, biased pawl that engages teeth of the spool to prevent the spool from rotating in the second reverse direction, but otherwise permits the spool to rotated in the first direction. For partial or complete release of the spool to permit the spool to freely rotated in the first and second directions, the device may include a tension release port, separate from the winding port. The user may use the tool release port by inserting the tool into the tension release port, whereby the user can rotate the tool to cause the pawl to disengage from the spool. A user may choose to loosen tension in the elongate member by briefly (i.e., for a first period of time) rotating the tool in tension release port in a first direction to disengage the pawl from the spool, followed by (e.g., a second period of time) rotating the tool in a second direction opposite the first direction to re-engage the pawl with the spool for partial or incremental release. Also, a user may insert the tool into the tension release port and rotate the tool in the first direction to disengage the pawl from the spool and leave it disengaged until tension is fully released.

In accordance with another embodiment, the housing is intended to be free standing in-line with the elongate member and not directly mounted to another article. In such an embodiment, the device can slide from side to side on the tension line before tension line is collected. This can allow the user to more easily position the adjustment device at a desired location (e.g., centrally on the elongate member) before winding. Also, the adjustment device may include a direct and rigid coupling of the control port with the spool axle and may include a ratcheting mechanism that allows the user to rotate the spool in the first direction to collect the elongate member around the axle. The ratcheting system may be configured to maintain tension in the elongate member and prevent the elongate member from unwinding from the spool axle. Specifically, in embodiments, torque can be transferred and maintained with respect to the device housing by way of a ratcheting plate surrounded by the housing that is coupled to the spool axle. The ratcheting plate may permit the spool and its axle to be rotated in the first direction, while not allowing the spool and its axle to rotate in the opposite direction with respect to the housing and thereby the strap.

During winding of the elongate member into the housing, it is possible that a channel volume between the housing and the spool can become completely filled with elongate member. If the channel volume becomes completely filled with elongate member, the device can continue to be used to collect additional tension line around the outside surface of the housing by continuing to rotate the tool port with the tool in the same rotational direction used for winding the elongate member into the channel volume.

The free standing line-tensioning adjustment device embodiment may include a release mechanism that includes a release button, which when pressed, can disengage the ratchet plate from the spool to allow the spool to freely rotate in two rotational directions about its axis. The button and the ratchet plate can be displaced in a direction parallel to the axis of the spool and perpendicular to a plane in which normal forces act on the ratchet plate. Since release can be actuated perpendicular to the line of force, the ratchet plate can be released with relatively low force requirement even when tension on the elongate member is relatively high.

In a modification to the free standing tension adjustment device, the device is provided with a gear protruding externally through the housing, and an add-external secondary spool that couples to the housing and rotates with the spool inside the housing. The secondary spool guides the elongate member about the outside of the housing and facilitates additional take up of elongate member should the internal spool become filled.

Another embodiment of an adjustment device may include a dial to collect slack or loose cable or lace before a tool is inserted. A user can slide their finger, palm, or other surface across the dial to collect the loose lace then apply use of the tool to increase the tension.

It is specifically intended that the embodiments are shown as exemplar illustrations of features that are intended to be combined in any suitable combination, provided that it is physically possible to combine the features together.

All the adjustment devices can be used with hand tools, ratcheting tools, power tools, or other tools. Tools can be connected to the adjustment devices for storage or can be stored separately. For increased mechanical advantage, a larger (longer lever arm) tools can be used. Also, to increase mechanical advantage or increase the speed of rotation of the spool, embodiments of the adjustment device can include gears transmissions to increase or decrease the applied mechanical force, specifically to increase mechanical advantage or facilitate fine adjustment, using e.g., planetary gear systems, worm gears, and/or other gear mechanisms.

In other embodiments of the adjustment device, a laterally displaceable wedge or detent protrudes radially or laterally into the tool port. Such wedge or detent may be radially or laterally displaceable outward form the control port by the tool upon insertion of the tool into the tool port. Such action of the wedge or detent can be used to disengage the spool to permit the spool to rotate freely either rotational direction. Also, removal of the tool from the control port can cause the wedge or detent to move inwardly into the control port to reengage and lock the spool.

The tool-operated adjustment devices in accordance with this disclosure can have relatively higher mechanical advantage and lower profile as compared to prior art devices. Given that a tool is used to operate the device to make the adjustments, the devices may be ideally suited for applications where it desirable to prevent unintended adjustment a flexible elongate member under tension in an article.

DETAILED DESCRIPTION

The present disclosure describes a number of embodiments of adjustment devices that employ a spool that interfaces to and supports at least one tension line. Thus, while some embodiments of the adjustment devices have been shown without connection to a tension line, all of the adjustment devices can be used with one or more tension lines. Note that each one the adjustment devices can be part of a fit system or a line tensioning system as described herein.

As used herein, a “tension line” refers to a flexible elongate member that can be gathered and wound onto a spool and unwound therefrom. The material of the tension line can be inelastic in nature or possibly have some elasticity. The tension line can be a cord, rope, cable, filament, or lace having a generally round profile, as well as flat straps having rectangular or square profiles. The material of the tension line can be any material typically used as a tension line in the same application. Thus, for a footwear application, the tension line used by the adjustment device in accordance with this description may be made from the same material currently in use for shoelaces. Also, the materials used may differ from those typically used for the application. The materials used for the tension line can include metal (e.g., steel) cable, and polyester webbing.

As used herein, a “fit system” refers to an adjustment device connected to a wearable article with at least one tension line (flexible elongate members such as straps, cables, wires, etc.) with one or more attachment points or interfaces to the article or device.

As used herein, a “line tensioning system” refers to an adjustment device connected to a non-wearable article or structure with at least one tension line (flexible elongate members such as straps, cables, wires, etc.) with one or more attachment points or interfaces to the article, device, or structure. Similar to fit systems, the attachment points or interfaces may decrease in distance relative to one another or relative to the line tensioning system, which can be referred to as contraction or shortening. The adjustment devices used in line tensioning systems may operate in space without being directly mounted to an article or structure.

FIGS.1to13show details of a first embodiment of an adjustment device100in accordance with an aspect of the disclosure. The device100is intended to be used with at least one a tension line that can be wound and collected by the device100and unwound and dispensed therefrom.FIGS.1to3show the device100assembled from its component parts shown in exploded views inFIGS.4and5.

The device100includes a housing10that includes a base12and a removable cover14. The housing10surrounds a spool16, shown in greater detail inFIGS.4and5. The base12defines a plurality of holes12athrough which the flexible elongate member20(FIGS.8and9) can extend to connect to an axle16aof the spool16on which the spool rotates about a first axis.

The base12has a mounting flange12bthat define notches12cthat can provide an anti-rotation feature for the device10. For example, the mounting flange12bmay be received into a molded or otherwise formed material702of a wearable article, such as a prosthetic socket700(shown inFIGS.10-11and40-42) such that the formed material secures the mounting flange12band protrudes into the notches12cto prevent rotation of the flange12brelative to the article.

The cover14defines a central opening14a. The opening14ais coaxial with a central longitudinal axis A-A of the device100. The central opening is shown as being a hexagonal opening, the shape of the opening defined in cross-section to the longitudinal axis. As shown inFIGS.4and5, the base12has threads12dthat mate with threads14bof the cover14to form a removable threaded connection between the cover14and the base12. The cover14can be disconnected from the base to permit a user to access the spool16and tension line in the housing. A hex tool mating with the hexagonal opening14acan be used to rotate the cover14relative to the base12to remove or reattach the cover14to the base12.

Turning toFIGS.4and5, the spool16is received and surrounded in the housing10. The spool is coaxially aligned with the cover14and the base12. The spool has an upper flange16band a lower flange16cconnected to ends of the axle16a, which is hollow in the example to receive a sliding retainer17, further details of which are described below.

The upper flange16bdefines a central opening16daligned with the opening14ain the cover14. The central opening16dis shown as being a hexagonal opening having a smaller diameter than the opening14a. The central opening16dleads into an upper end of a tool socket18that extends axially about a second axis and along axis A-A from the upper flange16bto a shoulder16a2extending from an inner surface16a1of the axle16a. Second axis is coaxial with first axis on axis A-A. The socket18is configured to receive a mating tool130(FIG.12). The socket18is configured to prevent relative rotation between the socket18and the tool130relative to axis A-A. Specifically, in the example shown, the socket18is defined as a six-sided bore18athat is configured to receive a six-sided tool, such as an end of a hex key130shown inFIG.12.

Also, the interior of the axle16aand the socket18are in communication with one another and are configured to receive a retainer17and to prevent relative rotation between the retainer17and the spool16. The retainer17includes a lower base17aand an upper protrusion17bconfigured to be received in and mate with the bore18aof the socket18from a lower end of the socket18to prevent relative rotation between the retainer17and the spool16. In the example shown, the upper protrusion17bof the retainer17has a hexagonal profile that is configured for axial reception along axis A-A into and out of the lower end of the bore18aof the socket18. The base17aof the retainer17is configured to engage the shoulder16a2which provides a positive stop to axial movement of the retainer17into the bore18aof the socket18.

The retainer17also defines a central bore17c(FIG.5) extending axially along axis A-A from a lower side of the base17a. In the example shown, the central bore17chas a hexagonal profile to receive and mate with a hexagonal central post15(FIG.4) extending axially along axis A-A and fixed to an upper surface of the mounting flange12bon the inside of the housing10. The engagement between the retainer17and the post15prevent relative rotation therebetween but permits the retainer17to translate along axis A-A relative to the post15.

The retainer17is biased axially along A-A towards the upper flange16bof the spool16with a biasing member19, shown as a spring. As shown inFIGS.6and10, when the bore18aaligns with the protrusion17bof the retainer17and no tool is inserted into the bore18aof the socket18, the retainer17is pushed upward into the bore18ain an engaged configuration, thereby preventing the spool16from rotating relative to the retainer17. Moreover, when the retainer17is in the engaged configuration with the spool16, the retainer17remains rotationally fixed to the post15. Thus, when the retainer17is in the engaged configuration with the socket18, the spool16is rotationally locked relative to the housing10.

As shown inFIG.12, the retainer17is configured to be disengaged from the spool16by inserting a tool130under manual force through holes14aand16dinto the bore18aof the socket18in a direction parallel to the axis A-A to connect the tool130to the socket18to translate the retainer17axially along A-A in the downward direction of the arrow B shown inFIGS.11,12, and13. Once the retainer17is displaced completely below the shoulder16a2, the spool16is rotationally disengaged from the retainer17so that the spool16can be rotated relative to the housing10about A-A using the tool130, as shown inFIG.13. The spool16can be rotated in either of the directions shown by arrows C and D inFIG.12.

When a user is finished rotating the spool16in either directions C or D, the user can align the bore18awith the retainer17so that the tool130can be withdrawn from the bore18ain a direction opposite arrow B inFIG.13while the retainer17seamlessly is reinserted into and engages the bore18ato retain tension in the elongate member and prevent the elongate member from unwinding.

FIG.8shows ends of a tension line20connected to the axle16aof the spool16and where the tension line20is not wound around the axle16aof the spool16.FIG.9shows the tension line20collected in the housing and wound around the axle16aof the spool16.FIG.10shows the device ofFIG.9with the wound tension line20and with the retainer17in its engaged configuration. With the retainer17in the engaged configuration, the spool16is rotationally locked relative to the housing10so that any tension in the tension line20cannot cause the tension line20to be unwound by rotation of the spool16in an unwinding direction. However, as shown inFIG.11, a user can reconfigure the retainer17by inserting the tool130to displace the retainer17from the bore18ato disengage the retainer17from the spool16, which can then permit the user to rotate the spool16to unwind the tension line20fully as shown inFIGS.8and11.

The user can be guided in aligning the bore18ainto the engagement position with the retainer17as follows. The base12includes a plurality of circumferentially spaced protrusions13. The lower flange16cof the spool16defines a plurality of notches or grooves16c1that are configured to mate with the protrusions13when the retainer17is aligned with the bore18aof the socket18(FIG.7). When the user rotates the spool16with the tool130, the engagement of the notches16c1and protrusions13provides haptic feedback to the user which can be felt in the hand of the user through the tool130. The haptic feedback can be used as an indicator to the user that the retainer17is in the engaged configuration and that the tool130can be removed from the socket18without loss of tension in the tension line20.

As shown most clearly inFIG.7, the spool axle16ahas a generally oval cross-sectional shape. The oval shape increases the capstan effect or spool's ability to transfer and maintain tension forces. Also, the axle16adefines diametrically opposed through holes16e, each of which is surrounded by a rounded or filleted rim16ffor strain relief of the elongate member that are configured to extend through the holes. The holes16emay be blind holes to retain a terminated end (e.g., an enlarged or flared end of the elongate member). In other embodiments, the elongate member may extend diametrically through the axle without terminating its ends at the axle16a. Also,FIGS.8and9show the gradual bend of the elongate member20around the curved surface16fthat can provide a strain relief to prevent damage to the elongate member20. The inner edges12a1(FIG.8) of the holes12amay also be rounded to protect the elongate member from abrasion and wear.

FIGS.8and9also show a collection volume21and a pathway between the spool16and the inner surface of the housing10. The collection volume21is defined as the space between the spool16and the interior surfaces of the housing10. As shown inFIGS.8and9, as the tension line20is collected, the collection volume21is filled with the tension line. Eventually, if the entire collection volume21is filled with the tension line20, the spool16cannot rotate any farther to collect additional tension line20.

InFIGS.10and11the adjustment device100is seated or otherwise embedded in a material22, which can be part of an article or may itself be a mounting member of the device100that can be attached to an article102, as shown inFIG.10. The material22may be molded around the housing10. In the example shown, a portion of the base12below the cap14is surrounded by the material22. Two cable routing passageways23are integrated into the material22and are in communication with the holes12a. The passageways23are lined with a cable housing24. Each cable housing24has an inner end (relative to the axis A-A) that is received in a bore12a2formed in the outer side of the base12. Each bore12a2aligns with a corresponding hole12a. The passageways and cable housings23and24extend outwardly (with respect to axis A-A) to outer ends from which the elongate member extends without being surrounded by the material22or cable housings24.

FIGS.14to19show details of a second embodiment of an adjustment device200. InFIGS.14to19elements corresponding to those of device100are shown incremented by “100”. The main differences between device100and device200lie in the construction of the spool116, retainer117, and posts115, between the base112and the cover114. The spool116includes a socket118with a central bore118a. As shown in detail inFIG.17, a plurality of teeth136extend along an inner surface of the axle116aaround the socket118. As shown inFIGS.14and15, the base112includes a stitch flange112b.

The retainer117is shown as a central hub117bsurrounded by an annular rim117a. Four radially extending teeth126extend from the annular rim117a. The rim117ais spaced radially from the hub117bby an annular groove117cthat is configured to receive a lower end of the socket118when the retainer117is engaged with the spool116. The teeth126are spaced 90 degrees around a perimeter of the rim117b. The teeth126are configured to engage the teeth136of the spool116when the retainer117is in an engaged configuration with the spool116, as shown inFIG.18.

The retainer117has a central blind hole117cthat is configured to retain a biasing member119, which urges the retainer axially along B-B towards the socket118. A central post115extends along axis B-B and is configured to support spring119and be received in the blind hole117c.

The retainer117defines four axially extending through holes125that are configured to receive and slide on four corresponding posts115aarranged around central post115. The posts115aextend from the base112parallel to axis B-B (FIG.15) and are arranged in a generally square pattern around the central post115. Each post115aextends through a corresponding spring119a. Each spring119aand119biases the retainer117upward towards the socket118. The arrangement of the four posts115aprevent relative rotation between the retainer117and the base112. The four posts115aare longer than the central post115b. The retainer117is configured to slide axially (parallel to B-B) along posts115aand115bbetween an engaged position and a disengaged position. The springs119aand119burge the retainer117upward towards the teeth of the spool. The teeth of the retainer are configured to engage the teeth of the spool when the notches116c1on the lower flange116cof the spool mate with protrusions113of the base112. When such alignment occurs, the retainer117can engage the teeth136of the spool116, as shown inFIG.18. In an engaged configuration, the teeth126of the retainer117are coupled to the teeth136of the spool116, the retainer117is coupled to the posts115a, and the spool116is rotationally locked and cannot rotate relative to the housing110about axis B-B.

Upon insertion of a tool, such as tool130, into the bore118aof the socket118, the retainer117can be translated along axis B-B down and out of engagement with the teeth136of the spool116, as shown inFIG.19. Once the teeth126of the retainer117are disengaged from the teeth136of the spool116, the spool116can be rotated in either rotational direction about axis B-B, and perpendicular to the base of the housing, by applying a rotational force to the tool.

The spool116has a lower flange116chaving a plurality of notches116c1. Twenty notches116c1are shown in the example embodiment that are spaced equally 18 degrees apart; thus, the spool116can be rotated in increments of 18 degrees. As such, the spool has defined stops that incrementally limit the smallest degree by which it can be rotated before the tool can be removed. Different increments can be similarly implemented by changing the rotational spacing of the notches116c1. Alternatively, the stops can be eliminated from the device.

FIGS.20to22show details of a third embodiment of a tool operated adjustment device300. InFIGS.20to22, elements corresponding to those of device200are incremented by 100. The device300includes the same structure as the device200with the following exceptions. The device300includes a spool216with an upper flange216bthat has sloped gear teeth216b1along its outer perimeter. The spool216has an axle216athat extends along axis C-C. The spool216is configured to rotate about axis C-C. Also, the device300includes a housing210with a cover214that defines an opening214athat leads to a tool socket218for receiving a tool for winding the spool216. As shown inFIGS.21A and22A, the spool216has diametrically opposed holes216eto connect to tension line260routed through openings212ain the base212of the housing210. The device300, however, does not include a retainer, like retainer117, to rotationally lock the spool relative to the housing.

Instead, the device300includes a ratcheting pawl mechanism240that is housed in the housing210and is pivotally coupled to the housing about an axis D-D, which is spaced from axis C-C of the axle216a. The mechanism240is operably configurable between a first configuration in which the mechanism240permits one way rotation of the spool216in a first direction (clockwise inFIG.21) and blocks rotation of the spool216in a second direction (counterclockwise inFIG.21), and a second configuration in which the mechanism240permits the spool216to rotate freely in both the first and second directions. The ratcheting pawl mechanism240is thus capable of maintaining tension in the tension line260when the tool is withdrawn from the socket218.

The ratcheting pawl mechanism240includes a pawl241pivotally coupled to and supported by the housing210. The pawl241is resiliently biased (i.e., with a spring242) in an engagement configuration in which the pawl241is engaged with the teeth216b1of the gear216bto permit rotation of the gear216b, and thus the entire spool216, in the first rotational direction (clockwise inFIG.21), while preventing rotation of the spool216in the second rotational direction (counterclockwise inFIG.21).

The pawl241is connected to a socket218cthat is accessible through an aligned hole214cin the cover214of the housing210. The socket218cis configured to receive a tool, which is preferably the same tool used in socket218. The socket218cis rotationally fixed to the pawl241so that rotation of the socket218cusing the tool can cause corresponding rotation of the pawl241about its axis of rotation D-D. In the example shown inFIG.21, a user wishing to disengage the pawl241from the gear216b, such as for reducing tension in a tension line wound around an axle216aof the spool216, can insert a tool into the second socket218cand rotate the tool counterclockwise inFIG.21. Once the pawl241is disengaged, either the inherent tension in the tension line260will cause extension of the tension line260to reduce tension and rotated the spool216in the second direction, or the user can use a second tool in the socket218to rotate the spool216in the second direction. The user can choose to loosen the tension line260by turning the tool in the second socket218cin the counterclockwise direction briefly then can turn the tool back in the clockwise direction to re-engage the pawl241with the teeth216b1for partial or incremental release. Alternatively, the user can turn the tool in the counterclockwise direction and leave it turned away until tension is fully released.

Turning now toFIGS.23A-23C, another embodiment of a tool operated adjustment device2000is shown. The device2000includes a housing with a spool2016having an axle2016a, as well as a spring-biased pawl2041, as previously described with respect to device300. Distinctions in adjustment device2000from device300include the following. The device2000includes a drive gear2070mounted on a parallel axle2074to axle2016a, and the spool2016is rotationally fixed relative to a driven gear2072meshing with the drive gear2070. The drive gear2070includes a control port2018for receiving the tool. When the pawl is released (discussed below) and the tool is rotated, the drive gear drives rotation of the driven gear and the spool.

In this exemplar embodiment shown, the drive gear2070has twice as many gear teeth as the driven gear such that the drive gear can drive the rotation of the spool in a 2:1 ratio. Any other suitable ratio can be provided between the gears. Alternatively, the drive gear2070can have fewer teeth to provide gear reduction and resulting finer adjustment of the driven gear. Such gear transmissions described in this embodiment are intended for application within any of the device within the scope of adjustment devices described herein.

In addition, in distinction from adjustment device300, the spring-biased pawl of device2000engages the drive gear2070. The pawl2041is manually releasable by rotating a portion of the pawl or knob2076connected thereto extending through the upper end of the cover2014such that only a single tool is required to operate the device. Such pawl release mechanism may be similarly used in association with device300. The pawl2041is operably configurable between a first configuration in which the mechanism permits one way rotation of the spool2016in a first direction and blocks rotation of the spool2016in a second direction, a second configuration in which the mechanism permits one way rotation of the spool2016in the opposite direction as the first configuration and blocks rotation of the spool2016in the opposite direction as the first configuration, and a third configuration in which the mechanism permits the spool2016to rotate freely in both the first and second directions.

Referring now toFIGS.24A and24B, another embodiment of a tool operated adjustment device2100is shown. The device2100includes a housing2110with a spool2116provided with an axle2116a. The housing2110includes an interior ring of gear teeth2180. A central star gear2182is coaxially situated over the spool2116. A central control port2118is provided in the upper end of the housing2110and into the star gear2182. A carrier plate2184is rotationally coupled with the spool2116. A set of three planet gears2186are rotatably mounted on pins on the carrier plate2184in an equidistantly spaced relationship. The planet gears2186are engaged with the gear teeth2180of the housing and the star gear2182. Three pawls2188are radially arranged on the retainer plate2184between the planetary gears2186and include a first portion2188afor engagement with the star gear2182and second portion2188bdefining a camming ramp that extends within the control port2118. The pawls2188are provided with a compression spring2190to bias the first portion2188ato interfere with the star gear2182and prevent rotation of the planetary gears2186when no tool is present in the control port2118. When the tool is inserted into the control port2118, the tool forces against the camming ramps2188bof the pawls to displace the second portion of the pawls away out of interference with the star gear2182so that the planetary gears2186can rotate and allow the spool2116to wind within the housing2114. The planetary gear system provides mechanical advantage to the system. The planetary gear system described in this embodiment is intended for application within any device within the scope of adjustment devices described herein.

FIGS.25to31shows details of a fourth embodiment of a tool operated adjustment device400. The adjustment device400is configured for use with a tension line strap (not shown). The device400includes a generally cylindrical housing410that extends along a central longitudinal axis E-E from a first base end410ato a second upper end410b. The housing410defines two diametrically opposite elongated tension line slots412through which tension line straps can extend into and out of the housing410.

A tool socket414is located at a first end410aof the housing for rotating a spool424(FIGS.28and29) (aligned with the slots412) housed inside the housing410. The first end410aof the housing410is connected to a retaining ring with a threaded connection. The retaining ring413retains the tool socket element414at the first end410aof the housing410. A release button416is located at the second end410bof the housing410that is opposite the first end410aof the housing410. The button416is configured to translate axially relative to the housing410along axis E-E, but the button416cannot rotate relative to the housing410due to the interlocking shape of the button416and the hole in the second end410bof the housing410that the button416extends through. The release button416is biased outwardly with respect to the second end410bof the housing410. A cover418is pivotally connected to the second end410bof the housing410and is configured to rotate about axis E-E parallel to central longitudinal axis E-E. When the button is not in use, the cover can be rotated over the button to conceal and protect the button from inadvertent actuation. When the button416is to be used, the cover418can be rotated about axis E-E to reveal the button, as shown inFIGS.24and30.

The body410includes a tool holder420that extends from an elongate outer side of the housing410. The tool holder420retains a tool422that is receivable in the tool socket414. The tool422shown is a hex key.

FIGS.26,27, and29show additional details of the spool424and ratcheting release mechanism426housed inside the housing410. The spool424includes a first flange415, a second flange417, and two elongated members419rigidly connected at their ends to the first and second flanges415,417. The tool socket414is rotationally fixed to the first flange415of the spool424. In the embodiment, the first flange415is integrally formed with the tool socket414, though this is not a requirement. The flanges415and417connect to the elongated members419so that there is an elongated gap419abetween the elongated members to receive and retain a tension line strap. The elongated members419have an overall oval profile for at least the same reasons as the oval profile of the axle16aof device100described herein. The entire spool424is configured to rotated in unison about axis E-E.

The second flange417of the spool is configured to connect to the ratcheting release mechanism426. Specifically, notches417aare formed along a peripheral edge of the second flange417. The notches are configured to engage pins421that rotationally couple the second flange417to the ratcheting release mechanism426as described in greater detail below.

The ratcheting release mechanism426includes a shaft coupler423, a ratcheting disc425, the release button416, a spring427, and a spring retainer429. The shaft coupler423is an annular member having an inner cylindrical surface defining an interior space and an outer cylindrical surface that is configured to rotate in unison with the spool424about inner surface of the housing410. As shown in greater detail inFIG.31, the second flange417of the spool424is received and seated in an inner side (relative to central axis F-F) of the interior space of the shaft coupler423. The second flange417is pivotally fixed to the shaft coupler423with the pins421so that the entire spool424and shaft coupler423rotate about axis E-E in unison (FIGS.25and27).

The spring427, spring retainer429, and ratcheting disc425are also disposed in the interior space of the coupler423. The spring427is positioned between the second flange417of the spool424and the spring retainer429. The ratchet disc425is positioned between the spring retainer429and the push button416. The push button has pins416athat extend through the ratchet disc425and spring retainer429to rotationally fix them all to one another so they all remain rotationally fixed together and thus remain rotationally fixed relative to the housing410due to the fact that the button416is rotationally fixed relative to the housing410.

The ratchet disc425, spring retainer429, and push button416are configured to translate along axis E-E within the interior space of the shaft coupler423. The spring427biases the ratchet disc425, spring retainer429, and push button416outward (relative to axis F-F). The inner cylindrical surface of the outer side (relative to the axis F-F) of the coupler423has inner teeth423athat are configured to engage ratchet pawls425aof the ratchet disc425when the push button416is in a first configuration in which the button extends outward from the second end410bof the housing410, as shown inFIGS.32and33.FIG.33shows ratchet disc425engaged with the inner teeth423aof the shaft coupler423. When the button416is pressed inward toward axis F-F, as shown inFIGS.30and31, the ratchet disc425is translated inwardly against the bias of the spring427(which is compressed), which disengages the ratchet pawls425afrom the inner teeth423aof the shaft coupler423. When the pawls425aof the ratchet disc425are disengaged from the inner teeth423a, the user can rotate the spool424in either the first or the second direction about the axis E-E directly using the tool422in the tool socket414. Also, if tension has been built up in a tension line connected to the spool424, pressing on the release button416will cause the spool424to unwind in the second rotational direction about axis E-E to reduce tension in the tension line.

The pawls425aof the ratchet disc425, when engaged with the inner teeth423aof the coupler423, permit the spool424to rotate in a first rotational direction about axis E-E when the socket414is rotated using the tool422, while preventing the spool424from rotating in a second rotational direction opposite the first direction. When the tool is released or withdrawn from the tool socket414, the pawls425aretain tension in the tension line. The tension can be released by disengaging the pawls425afrom the inner teeth423aof the shaft coupler423by pushing on the release button416.

Turning now toFIGS.34A-34C, a modification to the fourth embodiment is provided which facilitates collecting tension line at the exterior of the housing; i.e., to effectively make the housing of the adjustment device into a secondary spool. (The inner ratcheting assembly is the same as in adjustment device400and will not be further described here.) The modification adjustment device400′ includes the following. As shown inFIGS.34A-C, the adjustment device400′ bolts together, defining lateral bosses460′ on diametrically opposing sides of the housing410′. Gear teeth462′ are provided fixed to one end of the exterior of the housing410′. A removable cap464′ is provided that covers and exposes the gear teeth462′.

Referring toFIGS.34D-34F, a removable outer ratcheting assembly470′ is provided for coupling with the adjustment device400′. The ratcheting assembly470′ includes first and second ratchet plates472a′ and472b′, a release handle474′, a spring476′, first and second pivot bars478a′ and478b′, and optionally a spacer480′ with snap-fit receiver482′ for a tool402′. The adjustment device is assembled into recesses484′,486′ within the ratchet plates472′ and spacer480′, with the bosses460′ registering in the recesses and fixing rotation of the device relative to the plates. The ratchet plates472a′,472b′ and handle474′ are assembled about the adjustment device400′ with screws481′. The release handle474′ extends in a u-shape into ratchet plates and includes a pawl488′ at one end. The pawl488′ is biased by the spring476′ to interfere with the gear teeth462′. Referring toFIG.34F, while the pawl488′ is engaged, as the inner ratcheting assembly is activated with the tool402′ inserter and rotated within control port418′ (FIG.34E), the flexible elongate member490′ is wound first about the interior spool416′; then, once the interior spool is full, the elongate flexible member490′ is wound about the exterior of the housing. The pivot bars478a,478bprevent unwinding of the flexible elongate member490′. Pulling on the release handle474′ relative to the ratchet plates424a′ and472breleases the pawl488′ from interference with the gear teeth462′ so that the ratchet assembly can rotate relative to the adjustment device and allow unwinding of the flexible elongate member490′.

FIGS.35to38show details of a fifth embodiment of a tool operated adjustment device500. The device500has substantially corresponding structure to device400. One difference between device500and device400lies in the fact that the spool516of the device500is constructed to wind a tension line lace or cable rather than a strap. Thus, a smaller spool516is utilized. In addition, the housing510and entry/exit ports530,532are correspondingly smaller as well, and a stitch flange511is provided to the housing for integration of the device into an article, such as soft goods or a textile-based application.

An additional feature of device500includes a dial534rotationally fixed relative to the spool516and accessible from outside the housing. The dial534allows a user to collect slack or loose cable or lace before a tool is inserted into the control port514. The dial534offers minimal mechanical advantage, but allows the user to slide a finger, palm, or other surface across the dial to collect the loose lace then use the tool to increase the tension under the mechanical advantage of the tool (and/or any gears that may be integrated into the device, as described above).

Prior artFIG.39Aillustrates that prior art tensioning device that include an integrated line tensioner are bulky devices and protrude when applied to wearable articles on the human body. The larger profile of the prior art systems610and611can concentrate an impact force on the portion of the body to which the systems610and611are attached if a user falls or is impacted in that area of the user's body. In addition, the larger size can be aesthetically displeasing or unsuitable for certain wearable applications. By way of comparison, the adjustment devices620shown inFIG.39Bhave a lower profile. This is permitted, at least in part, because they use a separable tool rather than a line tensioner having an integrated-force applier; thus, they can be made smaller in size and better integrated with wearable articles. Further, in the event of a fall, force on the wearer is minimized as a result of the smaller size. In addition, by requiring use of a separate tool for tension and/or release, they are optimized to prevent inadvertent adjustment.

FIGS.40-66show various uses of adjustment devices into various exemplar articles. Such articles include wearable articles, in which the adjustment device operates to facilitate the fit of the article; sporting articles requiring application of tension, and utility articles requiring application of tension. It will be appreciated that adjustment device620of the systems640may take the form of any of the embodiments of an adjustment device described herein and is not limited to the schematics shown inFIGS.40-66. Furthermore, it is appreciated that the fields and applications shown and briefly described herein are not intended to be exhaustive or limiting but are merely examples.

FIGS.40-42shows fit systems620applied to a prosthetic socket700. For the socket shown inFIGS.40-42, an adjustment device640is coupled to the socket to apply or release tension on a cable645extending about all or a portion of a circumference of a prosthetic socket. For example, the device may be adjusted to tension the cable645to draw struts648a,648b,648c,648dof the socket radially inward or release tension to allow the struts to flex radially outward. Similarly, fit systems620could be applied to a prosthetic socket700to draw two sections or regions of the prosthetic socket700closer together or allow them to flex apart. Applying or relieving tension in the tension lines can enlarge or reduce the opening of the prosthetic or change the distribution of forces to adjust the fit of the prosthetic to a user. As shown inFIGS.41and42, each system620shown inFIG.40includes one adjustment device640connected to the cable645banded about the prosthetic socket700. As shown inFIG.42, a tool630is required to adjust tension to prevent inadvertent adjustment or limit adjustment to a prosthetist.

Referring toFIG.43, the adjustment device of the fit system may be mounted to the shell of the helmet710or may be left free to be positioned along the strap650b′ at an intermediate position between the sides of the helmet.

Turning toFIG.44, multiple fit systems620are connected to a ski boot720. The straps are banded around a leg portion and a foot portion of the boot and the adjustment devices of the straps may be mounted directly to the leg and foot portions of the boot.FIG.45shows fit systems620connected to snowboard boots730. Straps of the systems620are banded about the leg portion of the snowboard boots with the adjustment device640mounted directly to the boot. Also, straps of the fit system620are shown connected to the snowboard and include adjustment devices640mounted to the snowboard straps which can be used to adjust the connection of the snowboard boots to the snowboard.FIG.46shows a fit system620connected to a skate740, specifically an ice skate. The adjustment device640of the fit system620is mounted directly to the skate while the tension line is banded about the skate.

FIG.47shows an embodiment of a fit system620connected to a sandal750. The adjustment device640of the fit system620is mounted to one of the sandal straps while the tension line takes the place of a sandal closure strap.FIG.48shows a fit system620connected to a shoe760. The adjustment device640of the system620is mounted to the shoe and the strap extends across the tongue of the shoe.FIG.49shows a fit system620connected to a boot770, where the fit system is arranged identically to the system shown inFIG.46used with a skate740.FIG.50shows a fit system620with an adjustment device that is embedded into an upper of a shoe780with laces partially concealed by the upper (shown in broken lines) and laces that are visible across a tongue of the shoe.

FIG.51shows an embodiment of a fit system620used for an adjustable strap of a day pack790application. The tension line of the system620is connected to the day pack and the adjustment device640is not directly mounted to the day pack, but is spaced therefrom.FIG.52shows a fit system620used for an adjustable strap of a bag or backpack800(e.g., a camping backpack). The tension line of the system620is connected to the backpack and the adjustment device640is not directly mounted to the backpack but is spaced therefrom.

FIGS.53and54show uses of line tensioning systems620.FIG.53shows fit systems620used as straps of a suspended tent810. Each strap is connected to a corresponding adjustment device640. Each strap is configured to connect at one end to a tent and an opposite end to another structure (such as a tree) to suspend the tent above the ground. The line tensioning systems620may also be used for other suspension applications, such as mountaineering, rock-climbing, and rappelling. Similarly, the line tensioning system620may be used to tension sporting nets, such as for tennis, badminton, volleyball, table tennis, etc., and may be provided with the equipment therefor.FIG.54shows line tensioning systems620used as cargo tie down straps820connected to a truck bed. The line tensioning systems described herein can also be used as closures in carry-alls, suitcases, duffel bags, sport bags, and thus may be incorporated into such articles in accord with the intended scope herein.

FIGS.55-59show fit systems620applied to protectable wearable articles utilized in the field of motorsports. Specifically,FIG.55shows fit systems620applied to a protective vest900that can be used to adjust the fit of the vest to a user.FIG.56shows fit systems620applied to a protective suit910. The fit systems can be used to adjust the fit of the protective suit to a user's body at the locations shown inFIG.56.FIG.57shows a fit system620applied to a motorcycle boot920. As shown inFIG.57, two straps are banded about the boot: one strap banded about a leg portion of the boot and one strap banded about the foot. Separate adjustment devices640may be provided for each strap to independently tension each strap.FIG.58shows fit systems620applied to protective knee pads930where the strap is configured to be banded about the knee of a user and the adjustment device640can be used to adjust the fit of the straps.FIG.59shows a fit system620applied to protective pants940for adjusting the waist of the pants to fit a waist of a user.

FIG.60shows fit systems620applied to a prosthesis1000where the tension lines are straps banded about the socket of prosthesis.FIGS.61-64show various uses of the fits systems620in the field of orthotics (braces) for bracing bones and joints.FIG.61shows a fit system620utilized in an ankle orthosis1010. As shown inFIG.61, one strap is banded about a leg portion of the brace and one strap is banded about a foot portion of the brace. The adjustment device640of the fit system620is mounted to the device and controls tension in the two straps.FIG.62shows a fit system620applied to a back brace1020for thoracic lumbar sacral orthosis (TLSO) application. The strap of the system620is banded about the back and torso of the user and the adjustment device640is positioned over a user's chest for access to the user.FIG.63shows fit systems620applied to a knee brace1030or knee orthosis. One fit system is banded about the leg above the knee, while another fit system is banded about the leg below the knee. The adjustment devices640of the fit systems620can adjust tension in the straps to fit the straps to the user's leg.FIG.64shows fit systems620applied to a post-operative knee brace1040or knee immobilizer. The fit systems620are shown banded about the user's lower leg.

FIGS.65and66show fit systems620utilized in the field of clothing accessories and clothing. As shown inFIG.65, the fit system620is used as a belt for a pair of pants, which may be integrated into the pants1100. For example, the adjustment device640may be mounted to the pants with the strap of the fit system620banded about the waist of the pants.FIG.66shows the fit system620in the form of a belt1110. Where the fit system620is worn about the body, it is preferred to incorporate a tension limiter. However, in certain applications where the fit system620is intended to apply tension around the body, such as a tourniquet, it will be appreciated that the tension device of the fit system620would omit a tension limiter.

There have been described and illustrated herein several embodiments of a tension device, fit systems using the tension device, and a method of using the tension devices and fit systems. While particular embodiments of the invention have been described, it is not intended that the invention be limited thereto, as it is intended that the invention be as broad in scope as the art will allow and that the specification be read likewise. Thus, with respect to any embodiment, where a hex-shaped control port or similar structure has been described and corresponding hex-shaped tool for insertion therein and operation on the adjustment device, it is appreciated and intended that the control port or similar structure and working end of the tool can be any cooperative shapes that permit application of a torque. Thus, by way of example only, they can both have cross-sectional shapes that are polygonal, both have interfering but different cross-sectional polygonal shapes, or even have shapes with a combination of curves and/or at flat, provided that both the port and tool are not completely circular. Further, while particular tension line types have been disclosed, it will be appreciated that other tension line types may be used as well. For all of the embodiments, the line tensioning systems may be made from a plastic, metal, or a combination plastic and metal components. In addition, while particular types of plastics have been disclosed for parts of the embodiments, it will be understood that other suitable types of plastics can be used. For example, and not by way of limitation, acrylic and polycarbonate may be used. Moreover, while particular configurations have been disclosed in reference to housings for the tension devices, it will be appreciated that other configurations could be used as well. It will therefore be appreciated by those skilled in the art that, yet other modifications could be made to the provided invention without deviating from its scope as claimed.