Patent Publication Number: US-8117720-B2

Title: Rotary tensioning device

Description:
This application claims the benefit of U.S. Provisional Application No. 61/092,279, filed Aug. 27, 2008. 
    
    
     FIELD OF THE INVENTION 
     The present invention relates generally to the field of rotary tensioning devices, and more particularly to a rotary tensioning device used to tension straps of a device, such as, for example, wearable devices such as clothing, boots/shoes, protective devices, orthopedic devices, or prosthetic devices. 
     BACKGROUND 
     Rotary tensioning devices are used to provide relatively quick adjustment and tensioning of boots, shoes, or other devices, by running a cable or wire through cable guides positioned along opposed portions of the device to be drawn towards each other. Rotation of a knob in a first direction draws up the cable or wire to provide tension and rotation of the knob in a second direction lets out the cable or wire to reduce tension. 
     However, the knobs of typical rotary tensioning devices have a substantial size such that they project from the device to which the tensioning device is attached, such that the knob may catch on objects. Thus, the knob may be damaged, or the wearer may be injured from falling due to loss of balance caused by interaction of the knob with other objects. 
     Therefore, it is desirable to provide a low profile rotary tensioning device. However, some people, in particular elderly or infirm persons, may have difficulty manipulating a low profile knob, since such a low profile knob will not have much surface area for a wearer or user to grip. 
     It is also desirable to provide an indication of the amount of tension being applied so that a user or wearer can obtain reproducible amounts of tension with each use of the device. 
     The embodiments of the present disclosure provide a rotary tensioning device that is low profile when not being used to apply or reduce tension, but which is easier for any user, in particular elderly or infirm persons, to manipulate. Further, the disclosed embodiments of a rotary tensioning device utilize an indication system that provides a user with information to reproduce applied tensions between each subsequent use. 
     SUMMARY 
     A rotary tensioning device that is low profile when not being used to apply or reduce tension and that provides an easily manipulated tightening and loosening control mechanism is disclosed. A flip up handle is pivotally connected to a drive member and rotation of the handle and drive member rotates a driven member connected to a spool to take up or let out a cable or wire to apply or reduce tension in the cable or wire. When not being used to apply or reduce tension, the flip up handle is pivoted to lie flush against a housing of the spool to provide a low profile. A tension indicating device provides a user with a mechanism for reproducing tensions between uses. 
     The rotary tensioning device can include a base portion and a drive member rotatably positioned on the base portion. A driven member is also rotatably positioned on the base portion and is further configured to be rotated by rotation of the drive member. A housing at least partially surrounds the driven member. A handle is pivotally connected to the drive member and is configured to lie flush against the housing in a non-use position and is further configured to rotate the drive member in a use position. 
     The rotary tensioning device can also include a selectively releasable lock member configured to allow free rotation of the driven member in a first direction and to selectively allow or prevent rotation of the driven member in a second direction. The lock member can be in the form a pivoting lever that can be manipulated to pivot to an unlocked position and is biased to return to a lock position. 
     An indicator member that is rotatable with the driven member and visible through a view portion of the housing can be provided to indicate dosage or amount of tension in order to allow a user to reproduce the tension applied between succeeding uses. 
     The numerous advantages, features and functions of the various embodiments of a low profile rotary tensioning device will become readily apparent and better understood in view of the following description and accompanying drawings. The following description is not intended to limit the scope of the rotary tensioning device, but instead merely provides exemplary embodiments for ease of understanding. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a perspective view of one embodiment of a rotary tensioning device according to the disclosure, with the control mechanism in a non-use position; 
         FIG. 2  is a perspective view of the embodiment of  FIG. 1  with the control mechanism in a first use position; 
         FIG. 3  is a perspective view of the embodiment of  FIG. 1  with the control mechanism in a second use position; 
         FIG. 4  is a front perspective view of the embodiment of  FIG. 1  with the control mechanism in the non-use position; 
         FIG. 5  is a perspective view of the control mechanism and spool of the embodiment of  FIG. 1 ; 
         FIG. 6  is a perspective view of the control mechanism, driven member, and lock member of the embodiment of  FIG. 1 ; 
         FIG. 7  is a perspective view of the drive member, driven member, and lock member of the embodiment of  FIG. 1 ; 
         FIG. 8  is a top perspective view of the spool of the embodiment of  FIG. 1 ; 
         FIG. 9  is a side view of the spool of  FIG. 8  (with the wire or cable removed); 
         FIG. 10  is a bottom perspective view of the spool of  FIG. 8 ; 
         FIG. 11  is a bottom perspective view of the spool of  FIG. 8  rotated to take up the wire or cable; 
         FIG. 12  is a top perspective view of a variation of the spool of  FIG. 1 ; 
         FIG. 13  is a perspective view of the spool of  FIG. 12 ; 
         FIG. 14  is a top perspective view of the spool of  FIG. 12  rotated to take up the wire or cable; 
         FIG. 15  is a perspective view of the spool of  FIG. 14 ; 
         FIG. 16  is a perspective view of a variation of the rotary tensioning device of  FIG. 1  shown in combination with a strap to be tightened; 
         FIG. 17  is an expanded view of the strap of  FIG. 16 ; 
         FIG. 18  is a top view of another variation of the implementation of the rotary tensioning device of  FIG. 1  shown in combination with a support member and two straps to be tightened; 
         FIG. 19  is a variation of the support member shown in  FIG. 18 ; 
         FIG. 20  is a side view of the mounts of  FIG. 18 ; 
         FIG. 21  is a top view of the mounts of  FIG. 18 ; 
         FIG. 22  is a sectional view taken along line  22 - 22  of  FIG. 21 . 
     
    
    
     In the various figures, similar elements are provided with similar reference numbers. It should be noted that the drawing figures are not necessarily drawn to scale, but instead are drawn to provide a better understanding of the components thereof, and are not intended to be limiting in scope, but rather provide exemplary illustrations. It should also be noted that the features illustrated in a particular drawing may be utilized in an appropriate manner with any other suitable drawing figure. It should further be noted that the figures illustrate exemplary embodiments of a rotary tensioning device, and in no way limit the structures or configurations of a rotary tensioning device according to the present disclosure. 
     DETAILED DESCRIPTION OF VARIOUS EMBODIMENTS 
     A. Environment and Context of the Various Embodiments 
     The rotary tensioning devices described herein have many applications. For example, as described herein, the rotary tensioning device may be used in combination with one or more straps, which straps are connected to a cable or wire to be drawn up by the rotary tensioning device. The straps will typically be fixed at an end opposed to the end connected to the cable or wire, such that rotation of the rotary tensioning device in a first direction will build tension in the straps and rotation of the rotary tensioning device in a second direction will loosen the straps. 
     Such straps may be used in any suitable application, such as, for example, wearable items such as clothing, boots/shoes, protective devices, orthopedic devices, or prosthetic devices. The straps may also be used in any other application where strap tightening is desired, such as, for example, in securing items for transport or storage. Other uses of the rotary tensioning device in combination with a strap can include utilizing the rotary tensioning device and strap to adjust a varus/valgus angle, or other angles and orientations of an orthopedic device or as an adjustment mechanism for range of motion (ROM) of a hinge of an orthopedic device. The disclosed rotary tensioning devices are not to be limited for use in any particular environment, but may be used in any suitable environment where it is desired to provide reproducible tension to a device. It is also contemplated that the disclosed rotary tensioning devices can be used to provide tension to items other than straps. 
     As used herein, the words “cable” and “wire” are used interchangeably and have their ordinary meanings and refer to relatively long and relatively thin shaped metals, polymers, natural fibers, or any other suitable material, which may be single strand or multi-strand, and which may include friction reducing coatings thereon. 
     B. Detailed Description of a Rotary Tensioning Device 
     Referring to  FIGS. 1-11 , an embodiment of a rotary tensioning device  100  is illustrated. The rotary tensioning device  100  can be formed from any desired materials that are suitable for their intended purposes. For example, the components of the rotary tensioning device  100  can be formed from any suitable metals, plastics, composite materials, or any combination thereof. 
     The rotary tensioning device  100  includes a base  102 , which may be a self contained structure suitable for connection to an additional item, or which may be integrated into the structure of an additional item. For example, if the rotary tensioning device  100  is to be used as a component of an orthopedic brace, the base  102  may be integrated with the support structure of such an orthopedic brace. Alternatively, the base  102  can be separately formed and adhered or connected to the support structure of an orthopedic brace via suitable mechanisms, such as any type of welding, any type of mechanical connection, or in any other suitable manner. 
     The base  102  provides a supporting mechanism for the remaining components of the rotary tensioning device  100 . In particular, a first axle (not shown) and a second axle  106  are provided with the base  102 . 
     As shown best in  FIGS. 6 and 7 , the axles provide rotation points for a drive member  108  and a driven member  114 . Each of the drive member  108  and the driven member  114  are respectively provided with projections or teeth  110 ,  116 . The projections or teeth  116  of the driven member  114  are correspondingly shaped to the projections or teeth  110  of the drive member  108 . Therefore, rotation of the drive member  108  in a first direction causes a corresponding rotation of the driven member  114  in a first direction, and rotation of either the drive member  108  or the driven member  114  in a second direction causes a corresponding rotation of the corresponding drive member  108  or driven member  114  in a second direction. 
     The drive member  108  includes a projection  112  extending from a surface thereof. The projection  112  provides a pivot connection for a control mechanism, as will be further described below. 
     The driven member  114  includes a coupling recess  118  formed at a central portion thereof around the axle  106 . The coupling recess  118  is configured to receive a correspondingly shaped coupling projection  130  formed on a spool  128 , as will be discussed below in further detail. 
     As best illustrated in  FIGS. 2 ,  3 ,  6 , and  7 , a lock member or lever  120  is pivotally connected to the base  102  at the pivot point  122 . The lock member  120  includes an engaging portion  124  that is configured to selectively engage the projections or teeth  116  of the driven member  114  in order to allow free rotation of the driven member  114  in a first direction and to selectively prevent or allow rotation of the driven member  114  in a second direction. The engaging portion  124  can include a sloped surface that passes along and over the sloped surfaces of the projections or teeth  116  when the driven member  114  rotates in a first direction such that the driven member  114  is freely rotatable in the first direction. The engaging portion  124  can also include a linear surface that is configured to engage the linear surface cut-outs on the back portion of the projections or teeth  116 , such that rotation of the driven member  114  in a second direction is prevented via the engagement of the two respective linear surfaces. 
     A biasing member or spring  126  is arranged between the engaging portion  124  of the lock member  120  and a housing  144 . The biasing member  126  biases the lock member to a locking position to prevent rotation of the driven member  116  in the second direction by causing the engaging portion  124  to engage the projections or teeth  116  of the driven member  114 . The biasing member  126  further allows the sloped surface of the engaging portion  124  to rise along and pass over the sloped surfaces of the projections or teeth  116 . A user can manipulate the lever  120  to an unlocked position by pivoting the lever  120  about the pivot point  122  to disengage the engaging portion  124  from the projections or teeth  116  of the driven member  114  to allow the rotation thereof in the second direction. 
     In a variation, the lock member can be configured to selectively prevent rotation in both a first and second direction, such that a user would be required to move the lock member to an unlocked position to rotate the rotary tensioning device in either direction. 
     As best seen in  FIGS. 5 , and  8 - 11 , a spool  128  is configured to be coupled to the driven member  114 . The coupling projection  130  formed on one surface of the spool  128  is correspondingly shaped to be received within the coupling recess  118  formed in the driven member  114 . In this manner, the spool  128  is configured to rotate with the driven member  114 . 
     The spool  128  includes a wire or cable groove  132  formed between two spaced apart disks that form the top and bottom surfaces of the spool  128 . A wire or cable anchor or hole  134  is formed in the groove  132  to allow a wire or cable  136  to pass therethrough or to be anchored in the groove  132 . If the wire  136  passes through the hole  134 , the wire  136  can be anchored to a side of a recess formed in a central portion of the spool  128 . 
     As shown in  FIGS. 10 and 11 , the wire  136  extends from the hole or anchor  134 . Rotation of the spool  128  in a first direction causes the wire  136  to be taken up and wound around the spool  128  within the groove  132  in order to apply tension to the wire  136 . 
     As shown in  FIGS. 5 ,  8 , and  9 , a second coupling projection  138  is formed on the top surface of the spool  128  for coupling an indicator member  140  thereto. The indicating member  140  is in the form of a partial disk, which may be colored, painted, patterned, include lines, numbers, or other markings or indicia, or is otherwise contrasting in order to be distinguishable from the upper surface of the spool  128 . The indicating member  140  includes a coupling cut out  142  in a central portion thereof that is complementary shaped with the second coupling projection  138  formed on the top surface of the spool  128  so that the indicating member  140  rotates concurrently with the spool  128 . As described below, the indicating member  140  cooperates with a view portion or window  146  in the housing  144  to indicate to the user the amount of tension being applied to the wire  136 . 
     As best seen in  FIGS. 2 and 3 , a housing  144  is arranged to at least partially enclose the spool  128 , the indicating member  140 , and the driven member  114 . The housing has appropriate openings or apertures to allow the wire  136  and the locking member  120  to extend therethrough. The housing further has an appropriate opening or aperture to allow meshing of the drive member  108  with the driven member  114 . 
     Additionally, the housing  144  includes a view portion  146  in a top surface thereof which may be formed as an open cut out in the housing or a cut out enclosed with a transparent window portion. As can be seen, tension marks  148  are arranged along the outer periphery of the view portion  146 . Of course, the location of the tension marks  148  may be altered, such as, for example, along an inner periphery of the view portion  146 . The tension marks may also be indicated with lines and/or numbers to provide an indication of the degree of tensioning. As will be discussed in more detail below, the tension marks  148  cooperate with the contrast between the spool  128  and the indicating member  140  to indicate to a user the amount of tension being applied to a wire  136 . 
     As best shown in  FIGS. 1-6 , a control mechanism in the form of a flip up handle  150  is pivotally connected to the drive member  108  at the pivot  152  attached to the projection  112 . The pivot  152  can be formed of flanges extending from the handle  150  to sit astride opposed sides of the projection  112 . A pivot pin is inserted through a clearance hole defined between the two opposed sides of the projection  112 , and is press fit, secured by adhesive, or mechanically secured into each flange of the handle. 
     As can be seen from the illustrations, the handle  150  has at least a non-use position, in which the handle  150  is pivoted to lie flush against the upper surface of the housing  144 , and a use position, in which the handle  150  is pivoted to a substantially orthogonal upright position. 
     This configuration of a flip up handle provides the benefits of a low profile rotary tensioning device, such that when the handle  150  is in the non-use position, the rotary tensioning device is less likely to be hung up on objects. Therefore, the rotary tensioning device is less subject to damage. Further, when the rotary tensioning device is placed upon wearable devices or articles, the wearer or user is less likely to suffer an injury from being thrown off balance or falling over due to the rotary tensioning device catching on other objects. 
     In addition to the benefits of providing a low profile rotary tensioning device, this configuration also provides an easily manipulated handle  150  in the use position, such that infirm or elderly users, as well as ordinary users, can easily manipulate the handle to provide tensioning. Thus, this disclosed embodiment achieves the benefits of a low profile rotary tensioning device, while also avoiding drawbacks typically associated with a low profile rotary tensioning device. 
     Referring again to  FIGS. 1-4 , it is seen that the handle  150  has a shape generally corresponding to the shape of the housing  144 , such that when the handle  150  is pivoted to the non-use position, the handle  150  and the housing  144  form a generally contiguous, low profile structure. The handle  150  is thus generally in the shape of a substantially planar disk that provides two opposed surfaces for grasping by a user to rotate the handle  150 , and thus the drive member  108 , the driven member  114 , and the spool  128 . 
     In order to allow the user to manipulate the handle  150  from the non-use position to the use position, a lip portion  154  is provided at one end thereof. The lip portion  154  extends beyond the periphery of the housing  144 , so that, even though when the handle  150  is in the non-use position and forms a generally contiguous structure with the housing  144 , a user may grasp or otherwise engage the lip portion  154  to pivot the handle  150  from the non-use position to the use position. 
     As generally depicted in  FIGS. 2 and 3 , the rotation of the handle  150  causes rotation of the drive member  108 , the driven member  114 , the spool  128 , and the indicating member  140 . As can be seen from the figures, rotation of the handle thus causes the contrasting or differently colored indicating member  140  to rotate within the view portion  146  of the housing  144 . The contrasting or differently colored indicating member  140  forms an edge with the spool  128 , such that the edge defines the extent of the contrasting or differently colored indicating member  140 . The edge between the contrasting or differently colored indicating member  140  and the spool  128 , in conjunction with the tension indicators  148 , provide a user with a mechanism to indicate the amount of tension being applied to the wire  136 . In this manner, the amount of tension being applied to the wire  136  is reproducible between successive tensioning, loosening, and tensioning again of the wire  136 . This provides users, in particular users wearing an orthopedic device, with a mechanism to provide the same tension or dosage between successive uses of the device. In other words, on two or more different days of wearing and removing a device, the same amount of tension can be easily applied on each day. 
     As previously discussed, the locking member  120  allows rotation of the driven member  114 , via rotation of the handle  150  and drive member  108 , in a first direction to take up the wire  136  around the spool  128 . The wire  136  can be unwound from the spool  128  by manipulating the locking member  120  to an unlocked position and either rotating the handle  150  in a second direction or by pulling the wire  136  away from the spool  128  to cause the spool  128  to rotate in a second direction to unwind the wire  136  therefrom. Due to the tension present in the wire  136 , there will naturally be a tendency for the spool to begin rotating in the second direction upon release of the locking member  120 . The driven member  114  and the drive member  108  can either be configured such that rotation of the driven member  114  in the second direction either causes rotation of the drive member  108  in a corresponding second direction, or alternatively, does not cause rotation of the drive member  108 . 
     C. Detailed Discussion of a Variation of a Spool for Use in a Rotary Tensioning Device 
     A variation of a spool  168  for use with the rotary tensioning device  100  is shown in  FIGS. 12-15 . The spool  168  has generally the same configuration as spool  128 , but may be used for providing tension to two wires connected to two distinct straps. The spool  168  includes two opposed holes  134  defined within the groove  132 . A wire  136  is passed through each of the holes to extend from both sides of the spool  168 . 
     As shown in  FIGS. 12 and 13 , the wire  136  extends from two opposed sides of the spool  168 . The spool is then rotated approximately 180 degrees, or one end of the wire  136  is wrapped around the spool  168  within the groove  132  until both ends of the wire  136  extend generally from the same side of the spool  168 . 
     As shown in  FIGS. 14 and 15 , once the ends of the wire  136  extend from the same side of the spool  168 , essentially two wires are provided. Each of the two wires can then be connected to respective straps so that the rotary tensioning device can be used to provide tensioning to two straps simultaneously. 
     It is contemplated that the use of two stacked spools  168  would allow the simultaneous tightening of four straps, and additional stacked spools may be used to tighten a desired number of straps simultaneously. 
     D. Detailed Discussion of an Exemplary Use of a Rotary Tensioning Device 
     An exemplary use of a rotary tensioning device  100  is shown in  FIGS. 16 and 17 . The rotary tensioning device  100  is used in conjunction with a strap  156  for tightening thereof. The strap  156  is connected to a base or support at one end (not shown) and is attached to a wire  136  at the opposed end. The rotary tensioning device  100  is similarly attached to a base or support and is utilized to apply tension to the strap  156 . 
     The wire  136  is connected at both ends to a spool of the rotary tensioning device  100  in a manner previously discussed in order to form a loop extending from the spool. The strap  156  is connected to the loop via a strap clasp  158 . 
     The strap clasp  158  is hinged  160  at a midpoint thereof in order to fold over an end portion of the strap  156  that is itself folded over the loop, as shown in  FIG. 17 . Retention projections  162  are provided on each of the divided surfaces of the strap clasp  158  for engagement with the strap  156  to prevent the strap  156  from being removed from the strap clasp  158 . 
     The ends of the respective divided surfaces of the strap clasp  158  are formed with locking projections  164  and locking recesses  166  to allow the strap clasp  158  to be closed over the folded end of the strap  156 . The locking projections  164  and locking recesses  166  can be in the form of snap fitting projections and recesses to allow selective opening and closing of the strap clasp  158  in order to allow the strap  156  to be disengaged from the strap clasp  158 . This feature can be used for such wearable devices as orthopedic braces, so that a user may remove the brace when the use thereof is not necessary. 
     The rotary tensioning device  100  functions as previously discussed, such that rotation of the handle  150  in direction A causes rotation of the spool and indicating member in direction B, which translates to a tightening of the strap  156  in direction C. 
     E. Detailed Discussion of Another Exemplary Use of a Rotary Tensioning Device 
     Another exemplary use of a rotary tensioning device  100  is shown in  FIGS. 18-22 . In this exemplary embodiment, the rotary tensioning device  100  is connected to a support member  170 . The support member  170  further includes a slot or slots ( FIG. 19 )  172  that allow mounts  174  for straps  180  to translate therein. 
     The rotary tensioning device  100  for this configuration can utilize the spool  168  described above to provide simultaneous tightening of two straps during rotation of the rotary tensioning device  100  in direction D. Each of the straps  180  is connected to a wire  136  that passes through a wire slot  178  in the respective mount  174 . 
     As shown in  FIGS. 20-22 , the mounts  174  include a projection  176  that fits within and travels along the slot/s  172  to allow the straps  180  to translate in the direction indicated at E ( FIG. 18 ). A similar projection can be provided at the end of the straps  180  where the wires  136  attach thereto in order to aid with maintaining the straps  180  along the mounts  174  in direction F ( FIG. 18 ) during tensioning thereof. The wires  136  are retained in the wire slots  178  to further aid with providing tensioning of the straps  180  along the direction F. 
     The exemplary configuration of  FIGS. 18-22  allows a user to tension two straps simultaneously in a first direction, and also provides some lateral strap adjustment as needed, for example, to accommodate different geometries of a portion of an anatomy of a user. 
     F. Conclusion 
     The disclosed embodiments of a rotary tensioning device provide an improved low profile rotary tensioning device that provides an easily manipulated control mechanism for elderly or infirm persons. 
     It is understood that the size of the rotary tensioning device and the components thereof can be adjusted according to the needs of the tightening system. 
     Of course, it is to be understood that not necessarily all objects or advantages may be achieved in accordance with any particular embodiment of the invention. Thus, for example, those skilled in the art will recognize that the invention may be embodied or carried out in a manner that achieves or optimizes one advantage or group of advantages as taught herein without necessarily achieving other objects or advantages as may be taught or suggested herein. 
     The skilled artisan will recognize the interchangeability of various features from different embodiments. In addition to the variations described herein, other known equivalents for each feature can be mixed and matched by one of ordinary skill in this art to construct a rotary tensioning device in accordance with principles of the present invention. 
     Although this invention has been disclosed in the context of certain exemplary embodiments and examples, it therefore will be understood by those skilled in the art that the present invention extends beyond the specifically disclosed embodiments to other alternative embodiments and/or uses of the invention and obvious modifications and equivalents thereof. Thus, it is intended that the scope of the present invention herein disclosed should not be limited by the particular disclosed embodiments described above.