Patent Description:
The invention relates to a motorized lacing system as specified in appended independent claim <NUM> and to a method of making a motorized lacing system as specified in appended independent claim <NUM>. Additional embodiments of the invention are disclosed in the dependent claims.

Example methods and systems are directed to an article of footwear having an autolacing motor using an optical encoder based on a rotary drum. 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.

Articles of footwear, such as shoes, may include a variety of components, both conventional and unconventional. Conventional components may include an upper, a sole, and laces or other securing mechanisms to enclose and secure the foot of a wearer within the article of footwear. Unconventionally, a motorized lacing system may engage with the lace to tighten and/or loosen the lace. Additional or alternative electronics may provide a variety of functionality for the article of footwear, including operating and driving the motor, sensing information about the nature of the article of footwear, providing lighted displays and/or other sensory stimuli, and so forth.

In general, and particularly for articles of footwear oriented toward the performance of athletic activities, characteristics such as the size, form, robustness, and weight of the article of footwear may be of particular importance. Where the components of the article of footwear promote, for instance, a relatively tall, heavy, and/or fragile article of footwear, the capacity of the article of footwear to be effective in the performance of the athletic activity may be compromised.

One type of component that may be utilized within the context of electronics of an article of footwear, including within the motorized lacing system, is an optical encoder. An optical encoder may be utilized to track rotational movement of the motor and/or, e.g., a spool coupled to the motor and on which the lace is wound and unwound. By tracking the revolutions of the motor and/or the spool, a controller may obtain information about how much more the motor and/or spool may be turned to achieve a desired configuration of the lace. However, conventional optical encoders may create issues for the article of footwear such as those described above, including having a relatively high stack up and being relatively fragile.

Conventional optical encoders may be planar, e.g., a circle. The optical encoder may spin on an axis of the circle and an optical sensor positioned above or below the circle may sense the passage of the portions of the encoder. A three-dimensional optical encoder has been developed in the general shape of a drum or cylinder. As will be described in detail herein, the three-dimensional optical encoder may provide both ease of manufacture as well as an implementation that is both more compact than a conventional two-dimensional optical encoder and greater robustness.

<FIG> is an exploded view illustration of components of a motorized lacing system for an article of footwear, in an example embodiment. While the system is described with respect to the article of footwear, it is to be recognized and understood that the principles described with respect to the article of footwear apply equally well to any of a variety of wearable articles. The motorized lacing system <NUM> illustrated in <FIG> includes a lacing engine <NUM> having a housing structure <NUM>, a lid <NUM>, an actuator <NUM>, a mid-sole plate <NUM>, a mid-sole <NUM>, and an outsole <NUM>. <FIG> illustrates the basic assembly sequence of components of an automated lacing footwear platform. The motorized lacing system <NUM> starts with the mid-sole plate <NUM> being secured within the mid-sole. Next, the actuator <NUM> is inserted into an opening in the lateral side of the mid-sole plate opposite to interface buttons that can be embedded in the outsole <NUM>. Next, the lacing engine <NUM> is dropped into the mid-sole plate <NUM>. In an example, the lacing system <NUM> is inserted under a continuous loop of lacing cable and the lacing cable is aligned with a spool in the lacing engine <NUM> (discussed below). Finally, the lid <NUM> is inserted into grooves in the mid-sole plate <NUM>, secured into a closed position, and latched into a recess in the mid-sole plate <NUM>. The lid <NUM> can capture the lacing engine <NUM> and can assist in maintaining alignment of a lacing cable during operation.

<FIG> illustrates generally a block diagram of components of a motorized lacing system <NUM>, in an example embodiment. The system <NUM> includes some, but not necessarily all, components of a motorized lacing system such as including interface buttons <NUM>, a foot presence sensor <NUM>, and the lacing engine housing <NUM> enclosing a printed circuit board assembly (PCA) with a processor circuit <NUM>, a battery <NUM>, a receive coil <NUM>, an optical encoder <NUM>, a motion sensor <NUM>, and a drive mechanism <NUM>. The optical encoder <NUM> may include an optical sensor and an encoder having distinct portions independently detectable by the optical sensor. The drive mechanism <NUM> can include, among other things, a motor <NUM>, a transmission <NUM>, and a lace spool <NUM>. The motion sensor <NUM> can include, among other things, a single or multiple axis accelerometer, a magnetometer, a gyrometer, or other sensor or device configured to sense motion of the housing structure <NUM>, or of one or more components within or coupled to the housing structure <NUM>. In an example, the motorized lacing system <NUM> includes a magnetometer <NUM> coupled to the processor circuit <NUM>.

In the example of <FIG>, the processor circuit <NUM> is in data or power signal communication with one or more of the interface buttons <NUM>, foot presence sensor <NUM>, battery <NUM>, receive coil <NUM>, and drive mechanism <NUM>. The transmission <NUM> couples the motor <NUM> to a spool to form the drive mechanism <NUM>. In the example of <FIG>, the buttons <NUM>, foot presence sensor <NUM>, and environment sensor <NUM> are shown outside of, or partially outside of, the lacing engine <NUM>.

In an example, the receive coil <NUM> is positioned on or inside of the housing <NUM> of the lacing engine <NUM>. In various examples, the receive coil <NUM> is positioned on an outside major surface, e.g., a top or bottom surface, of the housing <NUM> and, in a specific example, the bottom surface. In various examples, the receive coil <NUM> is a qi charging coil, though any suitable coil, such as an A4WP charging coil, may be utilized instead.

In an example, the processor circuit <NUM> controls one or more aspects of the drive mechanism <NUM>. For example, the processor circuit 204can be configured to receive information from the buttons <NUM> and/or from the foot presence sensor 202and/or from the motion sensor <NUM> and, in response, control the drive mechanism <NUM>, such as to tighten or loosen footwear about a foot. In an example, the processor circuit <NUM> is additionally or alternatively configured to issue commands to obtain or record sensor information, from the foot presence sensor 202or other sensor, among other functions. In an example, the processor circuit 204conditions operation of the drive mechanism <NUM> on (<NUM>) detecting a foot presence using the foot presence sensor <NUM> and (<NUM>) detecting a specified gesture using the motion sensor <NUM>.

Information from the environment sensor <NUM> can be used to update or adjust a baseline or reference value for the foot presence sensor <NUM>. As further explained below, capacitance values measured by a capacitive foot presence sensor can vary over time, such as in response to ambient conditions near the sensor. Using information from the environment sensor <NUM>, the processor circuit <NUM> and/or the foot presence sensor <NUM> can update or adjust a measured or sensed capacitance value.

<FIG> is a depiction of an optical encoder <NUM> including a two-dimensional disk <NUM>, in an example embodiment. The optical encoder <NUM> may operate as the optical encoder <NUM> in the block diagram of <FIG>. The two-dimensional disk <NUM> is positioned with a major surface <NUM> facing toward the motor <NUM> with a shaft <NUM> of the motor <NUM> that engages with the transmission <NUM> (not depicted) extending through the approximate center <NUM> of the disk <NUM>. The disk <NUM> is secured to the shaft <NUM> so that when the shaft <NUM> turns so does the disk <NUM>. The disk <NUM> includes a plurality of alternately dark segments <NUM> and reflective segments <NUM>. An optical sensor <NUM> is positioned on a printed circuit board (PCB) <NUM>. The printed circuit board <NUM> may, owing to the orientation of the optical sensor <NUM> in relation to the disk <NUM>, be a different PCB than the PCB on which the processor circuit <NUM> and other components are positioned.

As the motor <NUM> turns the shaft <NUM> the disk <NUM> turns as well, causing the dark and reflective segments <NUM>, <NUM> to pass by the optical sensor <NUM> in turn. The optical sensor <NUM> outputs a signal indicative of each segment <NUM>, <NUM> that passes to the processor circuit <NUM>. The processor circuit <NUM> may be keyed to the passage of each segment <NUM>, <NUM> to identify how much the shaft <NUM> has turned and, by extension, how much the spool <NUM> will have turned.

However, the optical encoder <NUM> with the two-dimensional disk <NUM> may carry several disadvantages in relation to an optical encoder <NUM> having a three-dimensional disk <NUM>, as disclosed herein. In particular, the challenges of manufacturing the disk <NUM> precisely may raise costs and reduce reliability. Imprecise or "fuzzy" edges between segments <NUM>, <NUM> may provide for unreliability in the optical sensor <NUM> identifying each segment <NUM>, <NUM> as that segment <NUM>, <NUM> transitions within the view of the optical sensor <NUM>.

<FIG> is a depiction of a three-dimensional encoder <NUM>, in an example embodiment. The three-dimensional encoder <NUM> is a drum encoder, including a drum portion <NUM> and a securing portion <NUM> coupled to the cylindrical portion and configured to secure the three-dimensional encoder <NUM> to e.g., the motor shaft <NUM>. The securing portion may be solid or may be individual portions that extend between the drum portion <NUM> and the shaft <NUM>, e.g., spokes or the like.

As illustrated, the drum portion <NUM> is cylindrical and has a circular cross section, though any of a variety of suitable geometries are contemplated, including conical, octagonal, and the like. As with the two-dimensional disk <NUM>, the drum <NUM> includes a first plurality of segments <NUM>, e.g., dark segments, alternatingly positioned between a second plurality of segments <NUM>, e.g., reflective segments. The first and second plurality of segments <NUM>, <NUM> are positioned on an exterior surface <NUM> of the drum portion <NUM>.

<FIG> is a depiction of an optical encoder <NUM>, including the three-dimensional encoder <NUM>, in an example embodiment. The optical encoder <NUM> may operate as the optical encoder <NUM> in the block diagram of <FIG>. In addition to the three-dimensional encoder <NUM>, the optical encoder <NUM> includes an optical sensor <NUM>, including a first optical sensor <NUM> and a second optical sensor <NUM> each within an optical range <NUM> of the three-dimensional encoder <NUM>, the optical range <NUM> being a distance over which the first and second optical sensors <NUM>, <NUM> can differentiate between the first and second plurality of segments <NUM>, <NUM>. As such, the optical range <NUM> will be different between and among different types of first and second optical sensors <NUM>, <NUM>. In the event that external design requirements may necessitate a specific distance between the optical sensor <NUM> and the three-dimensional encoder <NUM>, first and second optical sensors <NUM>, <NUM> may be selected that have an optical range <NUM> at least as long as the distance.

The first optical sensor <NUM> is positioned on a first major surface <NUM> of the PCB <NUM> while the second optical sensor <NUM> is positioned on a second major surface <NUM> of the PCB <NUM>. In the illustrated example, the first and second optical sensors <NUM>, <NUM> have a vertical spacing <NUM> approximately equal to a height <NUM> of each individual one of the first and second plurality of segments <NUM>, <NUM>, e.g., within approximately five (<NUM>) percent of the height <NUM>. As such, each of the first and second optical sensors <NUM>, <NUM> will both tend to detect the same type of segment, i.e., will both detect dark segments or reflective segments. If each of the first and second optical sensors <NUM>, <NUM> do not detect the same type of segment, e.g., the first optical sensor <NUM> detects one of the first plurality of segments <NUM> and the second optical sensor <NUM> detects one of the second plurality of segments <NUM> (or vice versa), the inconsistency may be expected to be resolved soon in favor of both the first and second optical sensor <NUM>, <NUM> detecting the same type of segment <NUM>, <NUM>.

While a particular configuration of the optical sensor <NUM> is illustrated, it noted and emphasized that the number and orientation of optical sensors may be varied between and among different implementations. Thus, a further alternative example of the optical sensor <NUM> may include three or more individual optical sensors. However, in various examples, each optical sensor is positioned on one of the major surfaces <NUM>, <NUM> of the PCB <NUM>.

<FIG> illustrate the operation of an optical encoder <NUM> which is off center relative to a major axis <NUM> of the optical encoder <NUM>, in an example embodiment. In <FIG>, a center <NUM> of an aperture <NUM> in the securing section <NUM> through which the motor shaft <NUM> (not picture) may pass is offset by distance relative to the major axis <NUM>. In <FIG>, with the aperture <NUM> fixed about the shaft <NUM> (not pictured), the exterior surface <NUM> and, by extension, the first and second plurality of segments <NUM>, <NUM>, come to within a first distance <NUM> of the optical sensor <NUM>. In <FIG>, the optical encoder <NUM> having completed a half-rotation relative to in <FIG>, the exterior surface <NUM> comes to within a second distance <NUM> of the optical sensor <NUM>, the second distance <NUM> being greater than the first distance <NUM>, owing to the off-center aperture <NUM> being fixed about the motor shaft <NUM>.

Offsets between the major axis <NUM> and the center <NUM> of the aperture may be an unintended consequence of a manufacture process. However, because of the properties of the optical sensor <NUM>, the apparent height <NUM> (<FIG>) of each of the first and second plurality of segments <NUM>, <NUM> may remain the same, in contrast to the changes in the apparent size of the segments <NUM>, <NUM> of the disk <NUM> (<FIG>) of the two-dimensional optical sensor <NUM> in the event of a similar offset. As a result, such concentricity issues may merely result in a difference in focal distance of the optical sensor <NUM>. Differences in the focal distance may be resolved by the optical sensor <NUM> within the optical range <NUM> of the optical sensor <NUM>. As such, the optical encoder <NUM> may allow for greater variance in a manufacturing process than may be allowed in a manufacturing process of the optical encoder <NUM>, as well as be more robust to normal wear and tear during use.

<FIG> is a depiction of an alternative example of a three-dimensional encoder <NUM>, in an example embodiment. The three-dimensional encoder <NUM> may otherwise have the same properties as the three-dimensional encoder <NUM>. But rather than having the first and second plurality of segments <NUM>, <NUM> on an outside surface of the drum portion <NUM>, the three-dimensional encoder <NUM> includes the first and second plurality of segments <NUM>, <NUM> on an interior surface <NUM>. The three-dimensional encoder <NUM> may otherwise be utilized in an arrangement similar to that of the optical sensor <NUM>, with the optical sensors <NUM> positioned to sense the interior surface <NUM>.

<FIG> illustrate a manufacturing process for the three-dimensional encoders <NUM>, <NUM>, in an example embodiment.

In <FIG>, a sheet <NUM> of elongate first and second plurality of segments <NUM>, <NUM> is cut into individual strips <NUM>. The sheet <NUM> is made of any suitable material, such as Mylar, and the dark segments, e.g., the first plurality of segments <NUM>, are printed onto a major surface <NUM> of sheet <NUM>. The reflective segments, e.g., the second plurality of segments <NUM>, are untreated or substantially untreated Mylar.

In <FIG>, the strip <NUM> is folded so that the major surface <NUM>, i.e., the printed side, is either on an exterior surface <NUM> or an interior surface <NUM>, as desired. A first end <NUM> is secured to a second end <NUM> to make a loop.

In <FIG>, the strip <NUM> is coupled to a frame <NUM> to form the three-dimensional encoder <NUM>, <NUM>, as desired. The frame <NUM> includes the securing portion <NUM> and a drum <NUM> on which to fix the strip <NUM> to form the drum portion <NUM>.

Certain embodiments are described herein as including logic or a number of components, modules, or mechanisms. Modules may constitute either software modules (e.g., code embodied on a machine-readable medium or in a transmission signal) or hardware modules. A "hardware module" is a tangible unit capable of performing certain operations and may be configured or arranged in a certain physical manner. In various example embodiments, one or more computer systems (e.g., a standalone computer system, a client computer system, or a server computer system) or one or more hardware modules of a computer system (e.g., a processor or a group of processors) may be configured by software (e.g., an application or application portion) as a hardware module that operates to perform certain operations as described herein.

In some embodiments, a hardware module may be implemented mechanically, electronically, or any suitable combination thereof. For example, a hardware module may include dedicated circuitry or logic that is permanently configured to perform certain operations. For example, a hardware module may be a special-purpose processor, such as a field programmable gate array (FPGA) or an ASIC. A hardware module may also include programmable logic or circuitry that is temporarily configured by software to perform certain operations. For example, a hardware module may include software encompassed within a general-purpose processor or other programmable processor.

Accordingly, the phrase "hardware module" should be understood to encompass a tangible entity, be that an entity that is physically constructed, permanently configured (e.g., hardwired), or temporarily configured (e.g., programmed) to operate in a certain manner or to perform certain operations described herein. As used herein, "hardware-implemented module" refers to a hardware module. Considering embodiments in which hardware modules are temporarily configured (e.g., programmed), each of the hardware modules need not be configured or instantiated at any one instance in time. For example, where a hardware module comprises a general-purpose processor configured by software to become a special-purpose processor, the general-purpose processor may be configured as respectively different special-purpose processors (e.g., comprising different hardware modules) at different times. Software may accordingly configure a processor, for example, to constitute a particular hardware module at one instance of time and to constitute a different hardware module at a different instance of time.

Claim 1:
A motorized lacing system, comprising:
a motor (<NUM>), including a motor shaft (<NUM>);
a processor circuit (<NUM>);
an optical encoder (<NUM>, <NUM>, <NUM>), comprising:
a three-dimensional encoder (<NUM>, <NUM>) defining a major axis and having a surface having a first plurality of segments (<NUM>, <NUM>) positioned between a second plurality of segments (<NUM>, <NUM>), the first plurality of segments having a different light reflecting characteristic than the second plurality of segments, the three-dimensional encoder secured to the motor shaft such that the turning of the motor shaft causes the three-dimensional encoder to rotate about the major axis; and
an optical sensor (<NUM>, <NUM>), positioned within optical range (<NUM>) of the three-dimensional encoder, configured to output a signal to the processor circuit indicative of a detected one of the first and second plurality of segments;
wherein the processor circuit is configured to operate the motor based, at least in part, on the signal as received from the optical sensor; and
a printed circuit board (<NUM>) on which the processor circuit and the optical sensor are positioned, wherein the optical sensor comprises a first optical sensor (<NUM>) on a first major surface (<NUM>) of the printed circuit board and a second optical sensor (<NUM>) on a second major surface (<NUM>) of the printed circuit board on an opposite side of the first major surface.