Patent Description:
The subject matter disclosed herein generally relates to a tensioning system and reel member for an article of footwear.

Articles of footwear generally include two primary elements: an upper and a sole structure. The upper is often formed from a plurality of material elements (e.g., textiles, polymer sheet layers, foam layers, leather, synthetic leather) that are stitched or adhesively bonded together to form a void on the interior of the footwear for comfortably and securely receiving a foot. More particularly, the upper forms a structure that extends over instep and toe areas of the foot, along medial and lateral sides of the foot, and around a heel area of the foot. The upper may also incorporate a lacing system to adjust the fit of the footwear, as well as permitting entry and removal of the foot from the void within the upper. <CIT> and <CIT> relate to footwear lacing tensioning systems.

The invention is defined by the appended independent claim <NUM>. Additional embodiments are defined in the dependent claims.

Example methods and systems are directed to a tensioning system and reel member for an article of footwear. Examples merely typify possible variations. Unless explicitly stated otherwise, components and functions are optional and may be combined or subdivided, and operations may vary in sequence or be combined or subdivided. In the following description, for purposes of explanation, numerous specific details are set forth to provide a thorough understanding of example embodiments. It will be evident to one skilled in the art, however, that the present subject matter may be practiced without these specific details.

Conventionally, the lacing system of an article of footwear includes one or more laces threaded through eyelets or other lacing channels and which is tensioned or cinched manually by a wearer of the article of footwear or by an individual who is assisting the wearer. The lace may then be secured, e.g., by tying the ends of the lace together or by clasping the lace with a mechanical element, to preserve the tension on the lace.

A motorized lacing or tensioning system has been developed that couples a motor to a reel by way of a transmission. A lace, cable, or other elongate member is secured to the reel and threaded through the lacing channels. By turning the reel with the motor, the lace may be placed under or released from tension, thereby tightening or loosening, respectively, the lace and cinching or loosening the article of footwear.

However, the act of securing the lace to the reel presents technical challenges so as to prevent the lace from tangling with respect to itself or other objects or otherwise losing its freedom of movement with respect to the reel. The reel may desirably secure the lace and provide space for the lace to spool up on the reel while also allowing the lace to spool and unspool without tangling. However, such goals may, in various circumstances, be at odds with one another in conventional reels. Securing the lace with respect to the reel may tend to restrict the movement of the lace in a way that may result in increased tangling of the lace. The provision of space on the reel for the lace to spool may restrict locations to secure the lace, placing further limitations on the freedom of movement of the lace.

A reel has been developed which secures the lace with respect to the reel and provides space for the lace to spool while providing relatively greater freedom of movement and reduced risk of tangling in comparison with other reel designs. In particular, a reel member includes a shaft with at least one, and in various examples, at least three flanges extending from the shaft. One of the flanges, in an example a center flange, includes an aperture through which the lace is threaded. The end flanges define first and second shaft sections around which the lace is configured to spool.

The positioning of the aperture in the center flange provides a mechanism for securing the lace with respect to the reel member while still providing the lace with freedom of movement to reduce a likelihood of tangling. Friction on the lace may be reduced by chamfering the aperture. A screw or other fixation mechanism may secure the reel member to a transmission of the tensioning system.

<FIG> illustrates a schematic isometric view of an exemplary embodiment of article of footwear <NUM> that is configured with a tensioning system <NUM>. In the current embodiment, article of footwear <NUM>, also referred to hereafter simply as article <NUM>, is shown in the form of an athletic shoe. However, in other embodiments, tensioning system <NUM> may be used with any other kind of footwear including, but not limited to: hiking boots, soccer shoes, football shoes, sneakers, running shoes, cross-training shoes, rugby shoes, basketball shoes, baseball shoes as well as other kinds of shoes. Moreover, in some embodiments article <NUM> may be configured for use with various kinds of non-sports related footwear, including, but not limited to: slippers, sandals, high heeled footwear, loafers as well as any other kinds of footwear. As discussed in further detail below, a tensioning system may not be limited to footwear and in other embodiments a tensioning system could be used with various kinds of apparel, including clothing, sportswear, sporting equipment and other kinds of apparel. In still other embodiments, a tensioning system may be used with braces, such as medical braces.

For reference purposes, article <NUM> may be divided into three general regions: a forefoot region <NUM>, a midfoot region <NUM>, and a heel region <NUM>, as shown in <FIG> and <FIG>. Forefoot region <NUM> generally includes portions of article <NUM> corresponding with the toes and the joints connecting the metatarsals with the phalanges. Midfoot region <NUM> generally includes portions of article <NUM> corresponding with an arch area of the foot. Heel region <NUM> generally corresponds with rear portions of the foot, including the calcaneus bone. Article <NUM> also includes a medial side <NUM> and a lateral side <NUM>, which extend through each of forefoot region <NUM>, midfoot region <NUM>, and heel region <NUM> and correspond with opposite sides of article <NUM>. More particularly, medial side <NUM> corresponds with an inside area of the foot (i.e., the surface that faces toward the other foot), and lateral side <NUM> corresponds with an outside area of the foot (i.e., the surface that faces away from the other foot). Forefoot region <NUM>, midfoot region <NUM>, and heel region <NUM> and medial side <NUM>, lateral side <NUM> are not intended to demarcate precise areas of article <NUM>. Rather, forefoot region <NUM>, midfoot region <NUM>, and heel region <NUM>, and medial side <NUM>, lateral side <NUM> are intended to represent general areas of article <NUM> to aid in the following discussion. In addition to article <NUM>, forefoot region <NUM>, midfoot region <NUM>, and heel region <NUM> and medial side <NUM>, lateral side <NUM> may also be applied to a sole structure, an upper, and individual elements thereof.

For consistency and convenience, directional adjectives are also employed throughout this detailed description corresponding to the illustrated embodiments. The term "lateral" or "lateral direction" as used throughout this detailed description and in the claims refers to a direction extending along a width of a component or element. For example, a lateral direction of article <NUM> may extend between medial side <NUM> and lateral side <NUM>. Additionally, the term "longitudinal" or "longitudinal direction" as used throughout this detailed description and in the claims refers to a direction extending across a length or breadth of an element or component (such as a sole structure or an upper). In some embodiments, a longitudinal direction of article <NUM> may extend from forefoot region <NUM> to heel region <NUM>. It will be understood that each of these directional adjectives may also be applied to individual components of an article of footwear, such as an upper and/or a sole structure. In addition, a vertical direction refers to a direction perpendicular to a horizontal surface defined by the longitudinal direction and the lateral direction. It will be understood that each of these directional adjectives may be applied to various components shown in the embodiments, including article <NUM>, as well as components of a tensioning system <NUM>.

In some embodiments, article of footwear <NUM> may include a sole structure <NUM> and an upper <NUM>. Generally, upper <NUM> may be any type of upper. In particular, upper <NUM> may have any design, shape, size and/or color. For example, in embodiments where article <NUM> is a basketball shoe, upper <NUM> could be a high top upper that is shaped to provide high support on an ankle. In embodiments where article <NUM> is a running shoe, upper <NUM> could be a low top upper.

In some embodiments, sole structure <NUM> may be configured to provide traction for article <NUM>. In addition to providing traction, sole structure <NUM> may attenuate ground reaction forces when compressed between the foot and the ground during walking, running or other ambulatory activities. The configuration of sole structure <NUM> may vary significantly in different embodiments to include a variety of conventional or non-conventional structures. In some cases, the configuration of sole structure <NUM> can be configured according to one or more types of ground surfaces on which sole structure <NUM> may be used. Examples of ground surfaces include, but are not limited to: natural turf, synthetic turf, dirt, as well as other surfaces.

In different embodiments, sole structure <NUM> may include different components. For example, sole structure <NUM> may include an outsole, a midsole, and/or an insole. In addition, in some cases, sole structure <NUM> can include one or more cleat members or traction elements that are configured to increase traction with a ground surface.

In an exemplary embodiment, sole structure <NUM> is secured to upper <NUM> and extends between the foot and the ground when article <NUM> is worn. Upper <NUM> defines an interior void within article <NUM> for receiving and securing a foot relative to sole structure <NUM>. The void is shaped to accommodate the foot and extends along a lateral side of the foot, along a medial side of the foot, over the foot, around the heel, and under the foot. Upper <NUM> may also include a collar that is located in at least heel region <NUM> and forms a throat opening <NUM>. Access to the interior void of upper <NUM> is provided by throat opening <NUM>. More particularly, the foot may be inserted into upper <NUM> through throat opening <NUM>, and the foot may be withdrawn from upper <NUM> through throat opening <NUM>.

In some embodiments, article <NUM> can include a lacing system <NUM>. Lacing system <NUM> extends forward from the collar and throat opening <NUM> in heel region <NUM> over a lacing area <NUM> corresponding to an instep of the foot in midfoot region <NUM> to an area adjacent to forefoot region <NUM>. Lacing area <NUM> extends between a lateral edge <NUM> and a medial edge <NUM> on opposite sides of upper <NUM>. Lacing system <NUM> includes various components configured to secure a foot within upper <NUM> of article <NUM> and, in addition to the components illustrated and described herein, may further include additional or optional components conventionally included with footwear uppers.

In this embodiment, a plurality of strap members <NUM> extends across portions of lacing area <NUM>. Together with tensioning system <NUM> (described in detail below), plurality of strap members <NUM> assist the wearer to modify dimensions of upper <NUM> to accommodate the proportions of the foot. In the exemplary embodiments, plurality of strap members <NUM> extend laterally across lacing area <NUM> between lateral edge <NUM> and medial edge <NUM>. As will be further described below, strap members <NUM> and a lace <NUM> of tensioning system <NUM> permit the wearer to tighten upper <NUM> around the foot, and to loosen upper <NUM> to facilitate entry and removal of the foot from the interior void (i.e., through throat opening <NUM>).

In some embodiments, upper <NUM> includes a tongue <NUM> that extends over a foot of a wearer when disposed within article <NUM> to enhance the comfort of article <NUM>. In this embodiment, tongue <NUM> extends through lacing area <NUM> and can move within an opening between opposite lateral edge <NUM> and medial edge <NUM> of upper <NUM>. In some cases, tongue <NUM> can extend between a lace and/or strap members <NUM> to provide cushioning and disperse tension applied by the lace or strap members <NUM> against a top of a foot of a wearer. With this arrangement, tongue <NUM> can enhance the comfort of article <NUM>.

Some embodiments may include provisions for facilitating the adjustment of an article to a wearer's foot, including tightening and/or loosening the article around the wearer's foot. In some embodiments, these provisions may include a tensioning system. In some embodiments, a tensioning system may further include other components that include, but are not limited to, a tensioning member, lacing guides, a tensioning assembly, a housing unit, a motor, gears, spools or reels, and/or a power source. Such components may assist in securing, adjusting tension, and providing a customized fit to a wearer's foot. These components and how, in various embodiments, they may secure the article to a wearer's foot, adjust tension, and provide a customized fit will be explained further in detail below.

Referring now to <FIG>, article <NUM> includes an exemplary embodiment of a tensioning system <NUM>. Embodiments of tensioning system <NUM> may include any suitable tensioning system, including incorporating any of the systems disclosed in one or more of <CIT>, now <CIT>, and titled "Motorized Tensioning System"; <CIT>, now <CIT> and titled "Motorized Tensioning System with Sensors"; and <CIT>, now <CIT> and titled "Footwear Having Removable Motorized Adjustment System"; (collectively referred to herein as the "Automatic Lacing cases").

In different embodiments, a tensioning system may include a tensioning member. The term "tensioning member" as used throughout this detailed description and in the claims refers to any component that has a generally elongated shape and high tensile strength. In some cases, a tensioning member could also have a generally low elasticity. Examples of different tensioning members include, but are not limited to: laces, cables, straps and cords. In some cases, tensioning members may be used to fasten and/or tighten an article, including articles of clothing and/or footwear. In other cases, tensioning members may be used to apply tension at a predetermined location for purposes of actuating some components or system.

In an exemplary embodiment, tensioning system <NUM> includes a tensioning member in the form of a lace <NUM>. Lace <NUM> is configured to modify the dimensions of the interior void of upper <NUM> and to thereby tighten (or loosen) upper <NUM> around a wearer's foot. In one embodiment, lace <NUM> may be configured to move plurality of strap members <NUM> of lacing system <NUM> so as to bring opposite lateral edge <NUM> and medial edge <NUM> of lacing area <NUM> closer together to tighten upper <NUM>. Similarly, lace <NUM> may also be configured to move plurality of strap members <NUM> in the opposite direction to move lateral edge <NUM> and medial edge <NUM> further apart to loosen upper <NUM>. With this arrangement, lace <NUM> may assist with adjusting tension and/or fit of article <NUM>.

In some embodiments, lace <NUM> may be connected or joined to strap members <NUM> so that movement of lace <NUM> is communicated to plurality of strap members <NUM>. For example, lace <NUM> may be bonded, stitched, fused, or attached using adhesives or other suitable mechanisms to attach portions of lace <NUM> extending across lacing area <NUM> to each strap member of plurality of strap members <NUM>. With this arrangement, when tension is applied to lace <NUM> via tensioning system <NUM> to tighten or loosen lacing system <NUM>, lace <NUM> can move strap members <NUM> between an open or closed position.

In some embodiments, lace <NUM> may be configured to pass through various lacing guides <NUM> that route lace <NUM> across portions of upper <NUM>. In some cases, ends of lacing guides <NUM> may terminate adjacent to lateral edge <NUM> and medial edge <NUM> of lacing area <NUM>. In some cases, lacing guides <NUM> may provide a similar function to traditional eyelets on uppers. In particular, as lace <NUM> is pulled or tensioned, lacing area <NUM> may generally constrict so that upper <NUM> is tightened around a foot. In one embodiment, lacing guides <NUM> may be routed or located between layers of the material forming upper <NUM>, including any interior layers or linings.

In some embodiments, lacing guides <NUM> may be used to arrange lace <NUM> in a predetermined configuration on upper <NUM> of article <NUM>. Referring to <FIG>, in one embodiment, lace <NUM> is arranged in a serpentine or alternating sides configuration on upper <NUM>. In some other embodiments, lace <NUM> may be arranged, via lacing guides <NUM>, in different configurations.

In some embodiments, tensioning system <NUM> includes a reel member <NUM>. Reel member <NUM> is a component within a tensioning assembly <NUM> of tensioning system <NUM>. Reel member <NUM> is configured to be rotated around a central axis in opposite directions to wind and/or unwind lace <NUM> and thereby tighten or loosen tensioning system <NUM>.

In an exemplary embodiment, reel member <NUM> is a reel or spool having a shaft <NUM> running along the central axis and a plurality of flanges extending radially outward from shaft <NUM>. The plurality of flanges can have a generally circular or round shape with shaft <NUM> disposed within the center of each flange. The flanges assist with keeping the wound portions of lace <NUM> separated and organized on reel member <NUM> so that lace <NUM> does not become tangled or bird-nested during winding or unwinding when tensioning system <NUM> is tightened or loosened.

In an exemplary embodiment, reel member <NUM> may include a center flange <NUM> located approximately at a midpoint along shaft <NUM> of reel member <NUM>. Center flange <NUM> may include an aperture <NUM> that forms an opening extending between opposite faces of center flange <NUM>. Aperture <NUM> is configured to receive lace <NUM>. As shown in <FIG>, lace <NUM> extends through aperture <NUM> in center flange <NUM> from one side or face of center flange to the other side or opposite face. With this arrangement, portions of lace <NUM> are disposed on opposite sides of center flange <NUM> and lace <NUM> is interconnected to reel member <NUM>.

In one embodiment, reel member <NUM> may include at least three flanges on shaft <NUM> that are spaced apart from one another. In this embodiment, reel member <NUM> includes a first end flange <NUM>, center flange <NUM>, and a second end flange <NUM>. Center flange <NUM> is located along shaft <NUM> between first end flange <NUM> and second end flange <NUM>. First end flange <NUM> and second end flange <NUM> are located on shaft <NUM> at opposite ends of reel member <NUM> on either side of center flange <NUM>. First end flange <NUM> and/or second end flange <NUM> may assist with keeping portions of lace <NUM> that are wound on reel member <NUM> from sliding off the ends of reel member <NUM> and may also assist with preventing lace <NUM> from becoming tangled or bird-nested during winding or unwinding when tensioning system <NUM> is tightened or loosened.

In some embodiments, tensioning assembly <NUM> of tensioning system <NUM> may be located within a cavity <NUM> in sole structure <NUM>. Sole structure <NUM> can include an upper surface <NUM> that is disposed adjacent to upper <NUM> on a top of sole structure <NUM>. Upper surface <NUM> may be directly or indirectly attached or joined to upper <NUM> or a component of upper <NUM> to secure sole structure <NUM> and upper <NUM> together. Sole structure <NUM> may also include a lower surface or ground-engaging surface <NUM> that is disposed opposite upper surface <NUM>. Ground-engaging surface <NUM> may be an outsole or other component of sole structure <NUM> that is configured to be in contact with a ground surface when article <NUM> is worn.

In an exemplary embodiment, cavity <NUM> is an opening in sole structure extending from upper surface <NUM> towards lower surface <NUM>. Tensioning assembly <NUM> of tensioning system <NUM> may be inserted within cavity <NUM> from the top of sole structure <NUM>. In an exemplary embodiment, cavity <NUM> has an approximately rectangular shape that corresponds with a rectangular shape of tensioning assembly <NUM>. In addition, cavity <NUM> may be of a similar size and dimension as tensioning assembly <NUM> so that tensioning assembly <NUM> conformably fits within cavity <NUM>. With this arrangement, tensioning assembly <NUM> and related components may be protected from contact with a ground surface by lower surface <NUM> when article <NUM> is worn.

Referring now to <FIG>, an exploded view of article <NUM>, including sole structure <NUM>, upper <NUM>, lacing system <NUM>, and tensioning system <NUM> are illustrated. In this embodiment, the configuration of lace <NUM> through lacing guides <NUM> can be seen alternately extending across lacing area <NUM> of upper <NUM> between medial edge <NUM> on medial side <NUM> and lateral edge <NUM> on lateral side <NUM>.

In addition, to facilitate lace <NUM> being able to tighten and loosen tensioning system <NUM>, ends of lace <NUM> are anchored to upper <NUM> at different locations. As shown in <FIG>, a first anchor <NUM> secures one end of lace <NUM> to upper <NUM> near or adjacent to throat opening <NUM> in heel region <NUM> of upper <NUM> and a second anchor <NUM> secures the opposite end of lace <NUM> to upper <NUM> near or adjacent to forefoot region <NUM>. First anchor <NUM> and second anchor <NUM> may be attached or joined to upper <NUM> may any suitable mechanism, including, but not limited to, knotting, bonding, sewing, adhesives, or other forms of attachment.

<FIG> illustrates an exploded view of an exemplary embodiment of components of tensioning system <NUM> including reel member <NUM> and lace <NUM>. In some embodiments, tensioning system <NUM> can include tensioning assembly <NUM> that is configured to adjust the tension of components of lacing system <NUM>, including lace <NUM> and/or strap members <NUM>, to secure, adjust, and modify the fit of article <NUM> around a wearer's foot. Tensioning assembly <NUM> may be any suitable device for adjusting tension of a tensioning member, such as a lace or strap, and can include any of the devices or mechanisms described in the Automatic Lacing cases described above.

Referring to <FIG>, some components of tensioning assembly <NUM> are shown within a portion of a housing unit <NUM>. In some embodiments, housing unit <NUM> may be shaped so as to optimize the arrangement of components of tensioning assembly <NUM>. In one embodiment, tensioning assembly <NUM> includes housing unit <NUM> that has an approximately rectangular shape. However, it should be understood that the shape and configuration of housing unit <NUM> may be modified in accordance with the type and configuration of tensioning assembly used within tensioning system <NUM>.

In this embodiment, tensioning assembly <NUM> includes reel member <NUM> that is mechanically coupled to a motor <NUM>. In some embodiments, motor <NUM> could include an electric motor. However, in other embodiments, motor <NUM> could comprise any kind of non-electric motor known in the art. Examples of different motors that can be used include, but are not limited to: DC motors (such as permanent-magnet motors, brushed DC motors, brushless DC motors, switched reluctance motors, etc.), AC motors (such as motors with sliding rotors, synchronous electrical motors, asynchronous electrical motors, induction motors, etc.), universal motors, stepper motors, piezoelectric motors, as well as any other kinds of motors known in the art.

Motor <NUM> may further include a crankshaft <NUM> that can be used to drive one or more components of tensioning assembly <NUM>. For example, a gear <NUM> may be mechanically coupled to reel member <NUM> and may be driven by crankshaft <NUM> of motor <NUM>. With this arrangement, reel member <NUM> may be placed in communication with motor <NUM> to be rotated in opposite directions around a central axis.

For purposes of reference, the following detailed description uses the terms "first rotational direction" and "second rotational direction" in describing the rotational directions of one or more components about a central axis. For purposes of convenience, the first rotational direction and the second rotational direction refer to rotational directions about central axis of shaft <NUM> of reel member <NUM> and are generally opposite rotational directions. The first rotational direction may refer to the counterclockwise rotation of a component about the central axis, when viewing the component from the vantage point of a first end <NUM> of shaft <NUM>. The second rotational direction may be then be characterized by the clockwise rotation of a component about the central axis, when viewing the component from the same vantage point.

In some embodiments, tensioning assembly <NUM> may include provisions for powering motor <NUM>, including a power source <NUM>. Power source <NUM> may include a battery and/or control unit (not shown) configured to power and control tensioning assembly <NUM> and motor <NUM>. Power source <NUM> may be any suitable battery of one or more types of battery technologies that could be used to power motor <NUM> and tensioning system <NUM>. One possibly battery technology that could be used is a lithium polymer battery. The battery (or batteries) could be rechargeable or replaceable units packaged as flat, cylindrical, or coin shaped. In addition, batteries could be single cell or cells in series or parallel. Other suitable batteries and/or power sources may be used for power source <NUM>.

In the embodiments shown, motor <NUM>, power source <NUM>, reel member <NUM>, crankshaft <NUM>, and gear <NUM> are all disposed in housing unit <NUM>, along with additional components, such as control unit or other elements, which may function to receive and protect all of these components within tensioning assembly <NUM>. In other embodiments, however, any one or more of these components could be disposed in any other portions of an article, including the upper and/or sole structure.

Housing unit <NUM> includes openings <NUM> that permit lace <NUM> to enter into tensioning assembly <NUM> and engage reel member <NUM>. As discussed above, lace <NUM> extends through aperture <NUM> in center flange <NUM> of reel member <NUM> to interconnect lace <NUM> with reel member <NUM>. When lace <NUM> is disposed through aperture <NUM> of center flange <NUM>, lace <NUM> may include a first lace portion <NUM> located on one side of center flange <NUM> and a second lace portion <NUM> located on the opposite side of center flange <NUM>. Accordingly, openings <NUM> in housing unit <NUM> allow both first lace portion <NUM> and second lace portion <NUM> of lace <NUM> to wind and unwind around reel member <NUM> within the inside of housing unit <NUM> of tensioning assembly <NUM>.

Referring now to <FIG>, an enlarged view of an exemplary embodiment of reel member <NUM> is illustrated. In this embodiment, reel member <NUM> has a central axis that extends along a longitudinal length of reel member <NUM> from a first end <NUM> to a second end <NUM>. As described above, reel member <NUM> is configured to rotate about the central axis in a first rotational direction and an opposite second rotational direction to wind or unwind lace <NUM> around portions of shaft <NUM>. In addition, reel member <NUM> may include a screw <NUM> disposed at second end <NUM> that is configured to engage with one or more gear assembly components, including gear <NUM> and/or crankshaft <NUM>, so as to be in communication with motor <NUM>. With this configuration, motor <NUM> may rotate reel member <NUM> about the central axis in the first rotational direction and the second rotational direction.

In some embodiments, portions of shaft <NUM> of reel member <NUM> may be described with reference to the plurality of flanges extending away from shaft <NUM>. For example, a first shaft section <NUM> extends between first end flange <NUM> and center flange <NUM> and a second shaft section <NUM> extends between second end flange <NUM> and center flange <NUM>. Shaft <NUM> may also include a third shaft section <NUM> extending from first end flange <NUM> to first end <NUM> and a fourth shaft section <NUM> extending from second end flange <NUM> to second end <NUM>. In some embodiments, screw <NUM> may be disposed on fourth shaft section <NUM>.

In some embodiments, each of the plurality of flanges has two opposing faces with surfaces that are oriented towards opposite ends of reel member <NUM>. For example, first end flange <NUM> has an outer face <NUM> having a surface oriented towards first end <NUM> of shaft <NUM> and an opposite inner face <NUM> having a surface oriented towards second end <NUM>. Similarly, second end flange <NUM> has an outer face <NUM> having a surface oriented towards second end <NUM> and an opposite inner face <NUM> having a surface oriented towards first end <NUM> of shaft <NUM>. Center flange <NUM> includes a first face <NUM> and an opposite second face <NUM>. First face <NUM> of center flange <NUM> has a surface oriented towards first end <NUM> of shaft <NUM> and facing inner face <NUM> of first end flange <NUM>. Second face <NUM> of center flange <NUM> has a surface oriented towards second end <NUM> of shaft <NUM> and facing inner face <NUM> of second end flange <NUM>.

In an exemplary embodiment, center flange <NUM> includes aperture <NUM>, described above. Aperture <NUM> extends between first face <NUM> and second face <NUM> of center flange <NUM> and provides an opening that allows lace <NUM> to extend between the opposite sides or faces of center flange <NUM>. In some embodiments, center flange <NUM> extends radially outward from shaft <NUM> and aperture <NUM> is located on center flange <NUM> so as to be spaced apart from shaft <NUM>. In this embodiment, aperture <NUM> is located adjacent to a perimeter edge of center flange <NUM>. In different embodiments, the distance between the perimeter edge of center flange <NUM> and the location of aperture <NUM> may vary. For example, the distance may be determined on the basis of revolution rate of tensioning assembly <NUM> and/or motor <NUM> or may be determined on the basis of the desired tension within tensioning system <NUM>.

As shown in <FIG>, when lace <NUM> extends through aperture <NUM> in center flange <NUM>, lace <NUM> can include a first lace portion <NUM> disposed on one side of center flange <NUM> and a second lace portion <NUM> disposed on the opposite side of center flange <NUM>. In this embodiment, first lace portion <NUM> is disposed on the side of center flange <NUM> that corresponds with first face <NUM> and second lace portion <NUM> is disposed on the side of center flange <NUM> that corresponds with second face <NUM>. With this arrangement, lace <NUM> may be interconnected to reel member <NUM>.

As will be further described below, reel member <NUM> is operable to be rotated in the first rotational direction or the second rotational direction to wind or unwind lace <NUM> and thereby tighten or loosen tensioning system <NUM>. For example, motor <NUM> and/or an associated control unit of tensioning system <NUM> can be used to control rotation of reel member <NUM>, including automatic operation and/or based on user inputs. When tensioning system <NUM> is tightened, reel member <NUM> rotates while lace <NUM> is interconnected to center flange <NUM> at aperture <NUM>. This rotation causes first lace portion <NUM> and second lace portion <NUM> to be wound onto portions of shaft <NUM> on opposite sides of center flange <NUM>. Specifically, first lace portion <NUM> is wound onto first shaft section <NUM> and second lace portion <NUM> is wound onto second shaft section <NUM>.

In this embodiment, first face <NUM> of center flange <NUM> and inner face <NUM> of first end flange <NUM> serve as boundaries or walls on the ends of first shaft section <NUM> to assist with keeping first lace portion <NUM> located on first shaft section <NUM> of reel member <NUM> during winding and unwinding of lace <NUM> with tensioning assembly <NUM>. In a similar manner, second face <NUM> of center flange <NUM> and inner face <NUM> of second end flange <NUM> serve as boundaries or walls on the ends of second shaft section <NUM> to assist with keeping second lace portion <NUM> located on second shaft section <NUM> of reel member <NUM> during winding and unwinding of lace <NUM> with tensioning assembly <NUM>. With this arrangement, lace <NUM>, including first lace portion <NUM> and second lace portion <NUM>, may be prevented from getting tangled or bird-nested during operation of tensioning system <NUM>.

<FIG> illustrates a cross-sectional view of reel member <NUM> and shows the interconnection of lace <NUM> with reel member <NUM> within tensioning system <NUM>. In this embodiment, first lace portion <NUM> of lace <NUM> extends through aperture <NUM> in the surface of first face <NUM> of center flange <NUM> and second lace portion <NUM> of lace <NUM> outwards from aperture <NUM> in the surface of second face <NUM> on the opposite side of center flange <NUM>. With this arrangement, lace <NUM> is interconnected to reel member <NUM> via aperture <NUM> in center flange <NUM> such that rotation of reel member <NUM> about the central axis will cause first lace portion <NUM> and second lace portion <NUM> to respectively wind about first shaft section <NUM> and second shaft section <NUM>.

In some embodiments, tensioning system <NUM> is operable to be controlled between at least a tightened condition and a loosened condition. In different embodiments, however, it should be understood that tensioning system <NUM> may be controlled to be placed into various degrees or amounts of tension that range between a fully tightened and a fully loosened condition. In addition, tensioning system <NUM> may include predetermined tension settings or user-defined tension settings. <FIG> and <FIG> illustrate exemplary embodiments of tensioning system <NUM> being operated between a loosened condition (<FIG>) and a tightened condition (<FIG>). It should be understood that the method of tightening and/or loosening tensioning system <NUM> using tensioning assembly <NUM> may be performed in reverse order to loosen tensioning system <NUM> from the tightened condition to the loosened condition.

Referring now to <FIG>, an exemplary embodiment of tensioning system <NUM> in a loosened condition is illustrated. In this embodiment, a foot <NUM> of a wearer is inserted into article <NUM> with tensioning system <NUM> in an initially loosened condition. In the loosened condition, lacing system <NUM> and plurality of strap members <NUM> are unfastened or in an open position to allow entrance of foot <NUM> within the interior void of upper <NUM>. Lace <NUM> is connected to strap members <NUM> of lacing system <NUM> and is also interconnected to reel member <NUM> of tensioning assembly <NUM> by being disposed through aperture <NUM> in center flange <NUM> of reel member <NUM>. With this arrangement, winding of lace <NUM> around portions of reel member <NUM> will cause tension in lace <NUM> to pull plurality of strap members <NUM> of lacing system <NUM> to a closed position and tighten upper <NUM> around foot <NUM> when tensioning system <NUM> is in the tightened condition.

<FIG> illustrates an exemplary embodiment of tensioning system <NUM> in a tightened condition. In this embodiment, tensioning assembly <NUM> rotates reel member <NUM> in the first rotational direction (e.g., counterclockwise) about the central axis to apply tension to lace <NUM> and tighten tensioning system <NUM>. The interconnection of lace <NUM> to center flange <NUM> through aperture <NUM> causes first lace portion <NUM> to wind around first shaft section <NUM> and second lace portion <NUM> to wind around second shaft section <NUM> when reel member <NUM> is rotated in the first rotational direction. The tension applied to lace <NUM> and transmitted from lace <NUM> to plurality of strap members <NUM> moves lacing system <NUM> to a closed position to secure upper <NUM> around foot <NUM> when tensioning system <NUM> is in the tightened condition.

Similarly, rotation of reel member <NUM> can be made in the opposite second rotational direction to unwind lace <NUM> from portions of shaft <NUM> to return tensioning system <NUM> to the loosened condition, as shown in <FIG> above. In addition, in some embodiments, rotation of reel member <NUM> in the second rotational direction may be performed by motor <NUM>, by a user manually pulling on lace <NUM> and/or strap members <NUM>, or both.

In an exemplary embodiment, rotation of reel member <NUM> in either or both of the first rotational direction and the second rotational direction will cause lace <NUM> to wind or unwind substantially equally around portions of shaft <NUM> of reel member <NUM>. That is, the amount of first lace portion <NUM> wound on first shaft section <NUM> and the amount of second lace portion <NUM> wound on second shaft section <NUM> will be approximately equal on opposite sides of center flange <NUM> when tensioning system <NUM> is in the tightened condition. Similarly, during unwinding of lace <NUM> from reel member <NUM>, approximately equal portions of lace <NUM> are unwound from opposite sides of center flange <NUM> when tensioning system <NUM> is placed in the loosened condition from the tightened condition. That is, the amount of first lace portion <NUM> unwound or spooled out from first shaft section <NUM> and the amount of second lace portion <NUM> unwound or spooled out from second shaft section <NUM> will be approximately equal.

In some embodiments, a reel member may be provided with provisions to assist with distributing tension through a tensioning system across various portions of an article of footwear. <FIG> illustrate an alternate embodiment of a reel member <NUM> having a chamfered aperture <NUM>. Reel member <NUM> is substantially similar to reel member <NUM>, described above, but includes chamfered aperture <NUM> in place of aperture <NUM>. Chamfered aperture <NUM> is substantially similar to aperture <NUM>, but has a chamfered surface along a circumference of the opening forming aperture <NUM>. The chamfering along the circumference of chamfered aperture <NUM> can reduce friction and assist with sliding of lace <NUM> through chamfered aperture <NUM>. With this arrangement, chamfered aperture <NUM> can assist with adjusting tension of lace <NUM> in tensioning system <NUM> across various portions of an upper and/or article of footwear.

Referring now to <FIG>, reel member <NUM> has a central axis that extends along a longitudinal length of reel member <NUM> from a first end <NUM> to a second end <NUM>. As described above with regard to reel member <NUM>, reel member <NUM> is also configured to rotate about the central axis in a first rotational direction and an opposite second rotational direction to wind or unwind lace <NUM> around portions of a shaft, including a first shaft section <NUM>, a second shaft section <NUM>, a third shaft section <NUM>, and a fourth shaft section <NUM>. In addition, reel member <NUM> may include similar provisions disposed at second end <NUM>, such as a screw or other mechanism, that are configured to engage with one or more gear assembly components, including gear <NUM> and/or crankshaft <NUM>, so as to be in communication with motor <NUM> and rotate reel member <NUM> about the central axis in the first rotational direction and/or the second rotational direction.

In some embodiments, reel member <NUM> may be described with reference to the plurality of flanges extending away from the shaft. For example, first shaft portion <NUM> extends between a first end flange <NUM> and a center flange <NUM> and second shaft portion <NUM> extends between a second end flange <NUM> and center flange <NUM>. The shaft of reel member <NUM> may also include third shaft section <NUM> extending from first end flange <NUM> to first end <NUM> and fourth shaft section <NUM> extending from second end flange <NUM> to second end <NUM>.

In some embodiments, each of the plurality of flanges of reel member <NUM> has two opposing faces with surfaces that are oriented towards opposite ends of reel member <NUM>. For example, first end flange <NUM> has an outer face <NUM> having a surface oriented towards first end <NUM> and an opposite inner face <NUM> having a surface oriented towards second end <NUM>. Similarly, second end flange <NUM> has an outer face <NUM> having a surface oriented towards second end <NUM> and an opposite inner face <NUM> having a surface oriented towards first end <NUM>. Center flange <NUM> includes a first face <NUM> and an opposite second face <NUM>. First face <NUM> of center flange <NUM> has a surface oriented towards first end <NUM> and facing inner face <NUM> of first end flange <NUM>. Second face <NUM> of center flange <NUM> has a surface oriented towards second end <NUM> and facing inner face <NUM> of second end flange <NUM>.

In an exemplary embodiment, center flange <NUM> includes chamfered aperture <NUM>, described above. Chamfered aperture <NUM> extends between first face <NUM> and second face <NUM> of center flange <NUM> and provides an opening that allows lace <NUM> to extend between the opposite sides or faces of center flange <NUM>. In this embodiment, each opening of chamfered aperture <NUM> on first face <NUM> and second face <NUM> has a chamfered circumference around the opening. As shown in <FIG>, chamfered aperture <NUM> has a first chamfered surface <NUM> along the circumference of the opening on first face <NUM> of center flange <NUM> and a second chamfered surface <NUM> along the circumference of the opening on second face <NUM> of center flange <NUM>.

In some embodiments, first chamfered surface <NUM> and second chamfered surface <NUM> may be a sloped or angled edge extending around the circumference of the opening. The slope or angle of first chamfered surface <NUM> and/or second chamfered surface <NUM> can be sufficient to provide a smooth surface that reduces friction with chamfered aperture <NUM> when lace <NUM> is under tension within tensioning system <NUM>. In one embodiment, the slope or angle of first chamfered surface <NUM> and/or second chamfered surface <NUM> may be approximately <NUM> degrees. In other embodiments, however, the slope or angle of first chamfered surface <NUM> and/or second chamfered surface <NUM> may be larger or smaller to reduce friction between lace <NUM> and chamfered aperture <NUM>. In still other embodiments, first chamfered surface <NUM> and/or second chamfered surface <NUM> may have a curved or rounded shape.

As shown in <FIG> and <FIG>, chamfered aperture <NUM> may assist with distributing tension within tensioning system <NUM> across various portions of upper <NUM> and/or article <NUM>. <FIG> illustrates an example of distributing tension in lace <NUM> within tensioning system <NUM> to decrease or lessen the tension in a forefoot region and increase or heighten the tension in a midfoot region of an article of footwear. The tension of lace <NUM> within tensioning system <NUM> is adjusted when tensioning system <NUM> is in a loosed condition so that portions of lace <NUM> may freely slide through chamfered aperture <NUM> and change the amount of each of first lace portion <NUM> and second lace portion <NUM> that is associated with the forefoot region and midfoot region of the upper and/or article of footwear.

As shown in this embodiment, tensioning system <NUM> can include lace <NUM> and can be generally associated with a forefoot region <NUM> and a midfoot region <NUM> of an upper of an article of footwear. For example, forefoot region <NUM> and midfoot region <NUM> can correspond to forefoot region <NUM> and midfoot region <NUM> of article <NUM>, described above. Lace <NUM> repeatedly extends across the lacing area and is anchored to a portion the upper in midfoot region <NUM> at first anchor <NUM> and is also anchored to a portion of the upper in forefoot region <NUM> at second anchor <NUM>. First anchor <NUM> and/or second anchor <NUM> allow lace <NUM> to be tensioned by tensioning assembly <NUM> when wound around a reel member, such as reel member <NUM> and/or reel member <NUM>.

An amount of first portion <NUM> of lace <NUM> disposed in midfoot region <NUM> slides through chamfered aperture <NUM> in center flange <NUM> of reel member <NUM> to increase the amount of second portion <NUM> of lace <NUM> disposed in forefoot region <NUM>. As seen in <FIG>, a forefoot lace portion <NUM> of lace <NUM> in forefoot region <NUM> increases from an initial first separation distance D1 to an increased second separation distance D2. The increase from first distance D1 to second distance D2 causes tension of lace <NUM> in tensioning system <NUM> located in forefoot region <NUM> to decrease or lessen once tensioning system is in the tightened condition due to the increased amount of second lace portion <NUM> that is now disposed within forefoot region <NUM>. That is, by increasing the amount of lace <NUM> in forefoot region <NUM>, tension in tensioning system <NUM> across forefoot region <NUM> of the upper and/or article of footwear is lessened and a more comfortable and/or customized fit may be provided to the foot of a wearer.

Similarly, sliding an amount of lace <NUM> through chamfered aperture <NUM> will increase the tension of tensioning system <NUM> in midfoot region <NUM>. As seen in <FIG>, a midfoot lace portion <NUM> of lace <NUM> in midfoot region <NUM> decreases from an initial third separation distance D3 to a decreased fourth separation distance D4. This decrease from third distance D3 to fourth distance D4 causes tension of lace <NUM> in tensioning system <NUM> located in midfoot region <NUM> to increase or heighten due to the decreased amount of first lace portion <NUM> that is now disposed within midfoot region <NUM>. That is, by decreasing the amount of lace <NUM> in midfoot region <NUM>, tension in tensioning system <NUM> across midfoot region <NUM> of the upper and/or article of footwear is increased and a more comfortable and/or customized fit may be provided to the foot of a wearer.

Referring now to <FIG>, an example of distributing tension in lace <NUM> within tensioning system <NUM> to decrease or lessen the tension in a midfoot region and increase or heighten the tension in a forefoot region of an article of footwear is shown. In contrast to the example shown in <FIG>, in this case, an amount of second portion <NUM> of lace <NUM> disposed in forefoot region <NUM> slides through chamfered aperture <NUM> in center flange <NUM> of reel member <NUM> to increase the amount of first portion <NUM> of lace <NUM> disposed in midfoot region <NUM>. As seen in <FIG>, midfoot lace portion <NUM> of lace <NUM> in midfoot region <NUM> increases from an initial fifth separation distance D5 to an increased sixth separation distance D6. The increase from fifth distance D5 to sixth distance D6 causes tension of lace <NUM> in tensioning system <NUM> located in midfoot region <NUM> to decrease or lessen once tensioning system is in the tightened condition due to the increased amount of first lace portion <NUM> that is now disposed within midfoot region <NUM>. That is, by increasing the amount of lace <NUM> in midfoot region <NUM>, tension in tensioning system <NUM> across midfoot region <NUM> of the upper and/or article of footwear is lessened and a more comfortable and/or customized fit may be provided to the foot of a wearer.

Similarly, sliding an amount of lace <NUM> through chamfered aperture <NUM> will increase the tension of tensioning system <NUM> in forefoot region <NUM>. As seen in <FIG>, forefoot lace portion <NUM> of lace <NUM> in forefoot region <NUM> decreases from an initial seventh separation distance D7 to a decreased eighth separation distance D8. This decrease from seventh distance D7 to eighth distance D8 causes tension of lace <NUM> in tensioning system <NUM> located in forefoot region <NUM> to increase or heighten due to the decreased amount of second lace portion <NUM> that is now disposed within forefoot region <NUM>. That is, by decreasing the amount of lace <NUM> in forefoot region <NUM>, tension in tensioning system <NUM> across forefoot region <NUM> of the upper and/or article of footwear is increased and a more comfortable and/or customized fit may be provided to the foot of a wearer.

The tension in tensioning system <NUM> can be changed in this manner because of the interconnection between lace <NUM> and reel member <NUM> via chamfered aperture <NUM>. As described above, approximately equal amounts of lace <NUM> are wound around the shaft on opposite sides of center flange <NUM> when tensioning system <NUM> is in the tensioned condition. In this embodiment, by changing the amount of lace <NUM> that corresponds to first lace portion <NUM> in midfoot region <NUM> and second lace portion <NUM> in forefoot region <NUM>, the relative amount of tension applied in each of these regions will be changed when lace <NUM> is wound around reel member <NUM>. With this arrangement, tension of tensioning system <NUM> in midfoot region <NUM> and forefoot region <NUM> of an article of footwear can be adjusted by changing an amount of first lace portion <NUM> that is associated with midfoot region <NUM> and changing an amount of second lace portion <NUM> that is associated with forefoot region <NUM>.

In addition, first chamfered surface <NUM> and/or second chamfered surface <NUM> of chamfered aperture <NUM> in reel member <NUM> reduces friction between chamfered aperture <NUM> and lace <NUM> to assist with allowing the wearer to slide lace <NUM> through chamfered aperture <NUM> and to adjust the tension of lace <NUM> within tensioning system <NUM>.

<FIG> is a flowchart for making a tensioning system for an article of footwear, in an example embodiment. The article of footwear may be the article <NUM> or any other suitable article. Some or all of the operations may be optional and either implemented or omitted as appropriate or desired.

At <NUM>, a reel member is obtained. In an example, the reel member is configured to rotate about a central axis and comprises a shaft including a central axis running from a first end to a second end and at least one flange, including a first face opposite a second face, disposed along the shaft with the shaft running through a center of the at least one flange from the first face to the second face. In an example, the reel member is obtained by making the reel member according to operations <NUM> through <NUM>.

At <NUM>, a shaft including a central axis running from a first end to a second end is formed.

At <NUM>, a flange is formed along the shaft, including a first face opposite a second face, extending radially outward from the shaft. In an example, the flange is a center flange. In an example, the flange is disposed along the shaft with the shaft running through a center of the at least one flange from the first face to the second face.

At <NUM>, a first end flange is formed along the shaft.

At <NUM>, a second end flange is formed opposite the first end flange relative to the center flange.

At <NUM>, an aperture is formed extending through the flange from the first face to the second face aligned with the central axis. In an example, the aperture extends parallel to the central axis through from the first face to the second face of the flange.

At <NUM>, a gear is placed in communication with the reel member and a motor of a tensioning system to rotate the reel member about the central axis.

At <NUM>, the shaft includes a first end and a second end disposed at opposite ends along the central axis of the shaft, and a screw is secured at the second end. In an example, securing the screw secures the gear with respect to the reel member.

At <NUM>, a portion of a lace is extended through the aperture to interconnect the lace with the reel member. In an example, the lace includes a first end, a second end, and a middle portion, a first segment of the middle portion extending through the aperture, a second segment of the middle portion of the lace being proximate the shaft adjacent the first face and a third segment of the middle portion of the lace being proximate the shaft adjacent the second face inducing tension on the lace. In an example, extending the lace comprises placing equal portions of the lace on opposite sides of the flange.

At <NUM>, a motor is placed in communication with the reel member to rotate the reel member.

At <NUM>, the reel member is rotated about the central axis in a first rotational direction to wind the lace to tighten the tensioning system. In an example, the gear is coupled between the reel member and the motor and the motor rotates the reel member via the gear.

Claim 1:
A reel member (<NUM>, <NUM>) for a tensioning system (<NUM>) of an article of footwear (<NUM>), the reel member configured to rotate about a central axis, the reel member comprising:
a shaft (<NUM>) including the central axis running from a first end (<NUM>, <NUM>) to a second end (<NUM>, <NUM>); and
at least one flange (<NUM>, <NUM>), including a first face (<NUM>, <NUM>) opposite a second face (<NUM>, <NUM>), disposed along the shaft with the shaft running through a center of the flange from the first face to the second face, the flange extending radially outward from the shaft;
wherein the shaft includes a first portion (<NUM>, <NUM>) extending from the first face and a second portion (<NUM>, <NUM>) extending from the second face
wherein the at least one flange includes an aperture (<NUM>,<NUM>) extending parallel to the central axis through the flange from the first face to the second face, and the aperture is configured to receive a middle portion of a lace (<NUM>), and wherein the first and second portions are adapted to receive portions of the lace concurrently upon rotation of the reel member.