Patent Description:
The subject matter disclosed herein relates to a transmission for a motorized tensioning system for footwear, as disclosed in claim <NUM>, a method of assembling such a system and an article of footwear incorporating such a system. Preferred embodiments are disclosed in the dependent claims <NUM>-<NUM> and <NUM>-<NUM>, respectively.

Articles of footwear generally include two primary elements: an upper and a sole structure. The upper can include one or more elements that are configured to fit around and receive a foot. In some embodiments, the upper can form 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 securement system, such as a shoelace, straps, or other members, that can be used to adjust the fit of the footwear. The securement system can also permit entry and removal of the foot from the void within the upper. <CIT> relates to an automated tightening shoe.

The present disclosure can be better understood with reference to the following drawings and description. The components in the figures are not necessarily to scale, emphasis instead being placed upon illustrating the principles of the present disclosure.

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 each or all of these specific details.

Articles of footwear have conventionally utilized lacing mechanisms that involve manual manipulation of laces or other mechanisms, e.g., manually tying the laces, to secure the article of footwear to a foot of a wearer. However, alternative mechanisms have been developed that provide for the tightening of laces, cables, and the like utilizing motors, transmissions, and gears. Because such motors, transmissions, and gears may necessarily be contained within the article of footwear, may need to tighten the laces sufficient to hold the article of footwear in place during vigorous physical activity, and may need to be manufactured within typical cost restrictions of articles of footwear, the mechanical properties of such motors and gears may be relatively constrained in relation to various other implementations of motors, transmissions, and gears. In particular, factors such as size, torque, manufacturing yield, and cost may be relatively difficult to rationalize.

A motorized lacing tensioning system has been developed which utilizes a transmission with compound gear with a ring gear and elongate shaft gear as separate components. The separate components of the compound gear may, in conjunction with other components of the transmission, provide for certain advantages in not seen in alternative examples of tensioning system transmissions, including an improved manufacturing process and adaptability of the compound gear to modifications of the design to the transmission. Further, the compound gear may allow for a relatively compact transmission that may be effectively integrated with the rest of the tensioning system.

<FIG> illustrate an exemplary embodiment of an article of footwear <NUM>. As shown in <FIG> and <FIG>, the article of footwear <NUM> can include a securement system <NUM> and a tensioning system <NUM>. Various features of the footwear <NUM>, the securement system <NUM>, and tensioning system <NUM> will be discussed in detail below. It will be appreciated that the footwear <NUM>, securement system <NUM>, and tensioning system can incorporate features described in one or more of the documents <CIT>, and <CIT>, filed March <NUM>, <NUM>.

As will be discussed in detail, the securement system <NUM> can be used for selectively securing the footwear <NUM> to the wearer's foot and for selectively releasing the footwear <NUM> from the wearer's foot. Stated differently, the securement system <NUM> can tighten and secure the footwear <NUM> to the foot, and the securement system <NUM> can loosen and release the footwear <NUM> from the foot. In other words, the securement system <NUM> can move the footwear <NUM> between a secured position and a loosened position relative to the wearer's foot.

The tensioning system <NUM> can be used for actuating the securement system <NUM>. As such, the tensioning system <NUM> can be used to automatically secure the footwear <NUM> to the foot and/or to automatically loosen the footwear <NUM> from the foot.

The tensioning system <NUM> can be robust due to one or more features that will be discussed in detail below. As such, the tensioning system <NUM> can ensure that the footwear <NUM> will tighten and stay secured on the foot, even under relatively high loads that act to loosen the footwear <NUM> from the foot. Additionally, the tensioning system <NUM> can be configured so that the footwear <NUM> efficiently and effectively loosens from the foot when the wearer so chooses.

Also, the tensioning system <NUM> can be compact and lightweight. As such, the tensioning system <NUM> can be packaged within the footwear <NUM> inconspicuously.

Additionally, the tensioning system <NUM> can have a relatively simple design. For example, the tensioning system <NUM> can have a low total part count. Furthermore, the tensioning system <NUM> can have high manufacturability.

In the current embodiment of <FIG>, the article of footwear <NUM> is shown in the form of an athletic shoe. However, in other embodiments, the securement system <NUM> and tensioning system <NUM> can 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 the article of footwear <NUM> can 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, the tensioning system <NUM> may not be limited to footwear. For example, the tensioning system <NUM> can be used with sportswear, other clothing and apparel, sporting equipment, medical braces, and more without departing from the scope of the present disclosure.

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

In some embodiments, the article of footwear <NUM> can include a sole structure <NUM> and an upper <NUM>. The sole structure <NUM> can be configured to provide traction for the article of footwear <NUM>. In addition to providing traction, the sole structure <NUM> can attenuate ground reaction forces when compressed between the foot and the ground during walking, running or other ambulatory activities. The configuration of the sole structure <NUM> can vary significantly in different embodiments to include a variety of conventional or non-conventional structures. In some cases, the configuration of the sole structure <NUM> can be configured according to one or more types of ground surfaces on which the sole structure <NUM> can 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, the sole structure <NUM> can include different components. For example, the sole structure <NUM> can include an outsole, a midsole, and/or an insole. In addition, in some cases, the 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, the sole structure <NUM> is secured to the upper <NUM> and extends between the foot and the ground when the article of footwear <NUM> is worn. The upper <NUM> defines an interior void within the article of footwear <NUM> for receiving and securing a foot relative to the sole structure <NUM>. The void is shaped to accommodate the foot and can extend along the lateral side of the foot, along a medial side of the foot, over the foot, around the heel, and under the foot.

The upper <NUM> can also include a collar that is located in at least the heel region <NUM> and that forms a throat opening <NUM>. Access to the interior void of upper <NUM> can be provided by the throat opening <NUM>. More particularly, the foot can be inserted into the upper <NUM> through the throat opening <NUM>, and the foot can be withdrawn from the upper <NUM> through the throat opening <NUM>.

The upper <NUM> can also include a lacing area <NUM>. In some embodiments, the lacing area <NUM> can be an opening extending from the throat opening <NUM> toward the forefoot region <NUM> and defined between the medial side <NUM> and the lateral side <NUM>. The upper <NUM> can additionally include a tongue <NUM> in some embodiments. The tongue <NUM> can be disposed within the lacing area <NUM>.

As shown in the embodiment of <FIG>, the securement system <NUM> can include one or more strap members <NUM> that extend across portions of the lacing area <NUM>. Furthermore, as shown in <FIG> and <FIG>, the securement system <NUM> can also include at least one tensioning member <NUM>. The tensioning member <NUM> can be a shoelace, a cable, or other elongate member. The tensioning member <NUM> can also be flexible, but the tensioning member <NUM> can have a substantially fixed length in some embodiments. The tensioning member <NUM> can extend through one or more of the strap members <NUM>. Other portions of the tensioning member <NUM> can extend through hollow, elongate guide members <NUM>. Moreover, in some embodiments, the tensioning member <NUM> and the guides <NUM> can be enclosed by the upper <NUM> of the article of footwear <NUM>.

In some embodiments, the tensioning member <NUM> can extend in a serpentine fashion through the strap members <NUM> and the guides <NUM> as shown in <FIG>. Also, the tensioning member <NUM> can extend along the lacing area <NUM>, alternating between the medial side <NUM> and the lateral side <NUM> of the article of footwear <NUM>. Moreover, a first end <NUM> of the tensioning member <NUM> can be fixed to the upper <NUM> and/or the sole structure <NUM>. Likewise, a second end <NUM> of the tensioning member <NUM> can be fixed to the upper <NUM> and/or the sole structure <NUM>.

Additionally, in some embodiments, the tensioning member <NUM> can be attached to the tensioning system <NUM>, which is shown schematically in <FIG> and <FIG>. As will be discussed, the tensioning system <NUM> can include a motor <NUM> and a reel <NUM>. In some embodiments, the motor <NUM> and reel <NUM> can be encapsulated and supported within a housing <NUM>. Additionally, the housing <NUM> can be received within a pocket <NUM> defined within the article of footwear <NUM>, for example, within the sole structure <NUM>.

The motor <NUM> can selectively drive the reel <NUM> so that the reel <NUM> winds, and the tensioning member <NUM> spools on the reel <NUM>. The tensioning member <NUM>, in turn, can tighten the straps <NUM> against the wearer's foot for securing the upper <NUM> to the foot. Additionally, in some embodiments, the motor <NUM> can unwind the reel <NUM> so that the tensioning member <NUM> unspools from the reel <NUM> and the straps <NUM> loosen.

The tensioning system <NUM> can also include a transmission <NUM> that operably couples the motor <NUM> to the reel <NUM>. The transmission <NUM> can also be encapsulated and supported within the housing <NUM>. Generally, in some embodiments, the transmission <NUM> can transfer power and torque from the motor <NUM> to the reel <NUM>.

The transmission <NUM> can include one or more features that ensure the tensioning system <NUM> can secure the footwear <NUM> to the foot and retain the footwear <NUM> in the secured position. For example, the transmission <NUM> can provide a relatively high gear ratio for these purposes. Also, the transmission <NUM> can be compact and lightweight. Moreover, the transmission <NUM> can avoid the need for a clutch and or brake. Instead, the transmission <NUM> can provide a single, consistent gear reduction.

<FIG> and <FIG> are external and cutaway depictions, respectively, of the transmission <NUM> in relation to the tensioning system <NUM>, in an example embodiment. The transmission <NUM> can be arranged relative to a longitudinal axis <NUM> and a transverse, lateral axis <NUM>. It will be appreciated that the longitudinal axis <NUM> and lateral axis <NUM> are included for reference purposes and to aid in the discussion of the transmission <NUM>.

The motor <NUM> can be of any suitable type, such as an electric motor. Also, the reel <NUM> can be rotatable. As the reel <NUM> rotates in one direction, the reel <NUM> can take up slack and increase tension in the tensioning member <NUM> (<FIG>) for tightening the footwear <NUM> on the wearer's foot. As the reel <NUM> rotates in the opposite direction, the tensioning member <NUM> can unwind from the reel <NUM> so that tension in the tensioning member <NUM> decreases and so that the footwear <NUM> loosens from the foot.

The motor <NUM> can include a motor shaft <NUM>, and the reel <NUM> can include a reel shaft <NUM>. The motor shaft <NUM> can include a first end <NUM> and a second end <NUM>. The reel shaft <NUM> can also include a first end <NUM> and a second end <NUM>. In some embodiments, the motor shaft <NUM> can be elongate with a substantially straight longitudinal axis <NUM>. Likewise, in some embodiments, the reel shaft <NUM> can be elongate with a substantially straight longitudinal axis <NUM>. The motor shaft <NUM> can rotate about the axis <NUM>, and the reel shaft <NUM> can rotate about the axis <NUM>. Thus, the axis <NUM> can be an axis of rotation for the motor shaft <NUM>, and the axis <NUM> can be an axis of rotation for the reel shaft <NUM>.

In some embodiments, both the axis <NUM> of the motor shaft <NUM> and the axis <NUM> of the reel shaft <NUM> can be substantially parallel to each other. For example, both the axis <NUM> and the axis <NUM> can be substantially parallel to the longitudinal axis <NUM>. Also, in some embodiments, the motor shaft <NUM> can protrude from the motor <NUM> in the same direction that the reel shaft <NUM> protrudes from the reel <NUM>. Furthermore, the motor shaft <NUM> and the reel shaft <NUM> can be spaced apart along the transverse axis <NUM>.

The transmission <NUM> of the tensioning system <NUM> can include a gear train <NUM> that includes a plurality gears that are arranged and enmeshed in a sequence. The gear train <NUM> can transfer torque and power from the motor shaft <NUM> to the reel shaft <NUM>.

The transmission <NUM> can also include one or more intermediate shafts that support respective gears of the gear train <NUM>. For example, the transmission <NUM> can include a first intermediate shaft <NUM> and a second intermediate shaft <NUM>. In some embodiments, the first intermediate shaft <NUM> and the second intermediate shaft <NUM> can be supported by a first support member <NUM> and a second support member <NUM>. In various examples, the first support member <NUM> and the second support member <NUM> can be supporting plates or other structures configured to seat ends <NUM>, <NUM> of the first intermediate shaft <NUM> and ends <NUM>, <NUM> of the second intermediate shaft <NUM>.

As will be discussed, the gear train <NUM> can provide a predetermined gear ratio and a predetermined gear reduction. Accordingly, as torque is transferred from the motor shaft <NUM> to the reel shaft <NUM>, the gear train <NUM> can reduce rotational speed while increasing torque. The gear ratio/reduction can be selected to provide reliable and effective power transfer from the motor shaft <NUM> to the reel shaft <NUM> when tightening and loosening the footwear <NUM>. Also, it will be appreciated that once the footwear <NUM> is tightened on the foot, various forces can act to loosen the footwear <NUM>. However, the gear ratio/reduction can be selected so the tensioning system <NUM> can resist these forces and to prevent inadvertent loosening of the footwear <NUM> from the foot.

The gear train <NUM> can have various configurations without departing from the scope of the present disclosure. However, it will be appreciated that the gear train <NUM> can vary from the illustrated embodiments without departing from the scope of the present disclosure.

The gear train <NUM> can include a plurality of gears, including a first gear <NUM>, a second gear <NUM>, a third gear <NUM>, a fourth gear <NUM>, a fifth gear <NUM>, a sixth gear <NUM>, a seventh gear <NUM>, an eighth gear <NUM>, a ninth gear <NUM>, a tenth gear <NUM>, an eleventh gear <NUM>, and a twelfth gear <NUM>. In some embodiments, one or more of the gears of the gear train <NUM> can be spur gears. However, the gears can be configured otherwise without departing from the scope of the present disclosure.

The gears of the gear train <NUM> can have predetermined features that provide the desired gear ratio/reduction. For example, the gears can have predetermined diameters, pitch diameters, and other similar dimensions that are measured in the lateral direction <NUM>. Moreover, the number of teeth and the tooth profile of the gears can be preselected. Additionally, one or more gears can have a predetermined width, which is measured in the longitudinal direction <NUM>. Moreover, the gears can be made out of predetermined materials, such as polymers, metals, and/or composites.

The first gear <NUM> can be mounted for rotation on the motor shaft <NUM>, proximate the second end <NUM>. In some embodiments, the first gear <NUM> can be rotationally fixed to the motor shaft <NUM> such that rotation of the motor shaft <NUM> causes synchronous rotation of the first gear <NUM>. The first gear <NUM> can be enmeshed with the second gear <NUM>.

The second gear <NUM> can be mounted on the first intermediate shaft <NUM>. In some embodiments, the second gear <NUM> can be mounted proximate a first end <NUM> of the first intermediate shaft <NUM>. Also, in some embodiments, the second gear <NUM> can be mounted for rotation relative to the first intermediate shaft <NUM>. For example, the second gear <NUM> can be mounted on the first intermediate shaft <NUM> via a bearing that allows the second gear <NUM> to rotate independent of the first intermediate shaft <NUM>.

The third gear <NUM> can also be mounted on the first intermediate shaft <NUM>, proximate the second gear <NUM>. In some embodiments, the third gear <NUM> can be mounted for rotation relative to the first intermediate shaft <NUM>. For example, the third gear <NUM> can be mounted on the first intermediate shaft <NUM> via a bearing that allows the third gear <NUM> to rotate independent of the first intermediate shaft <NUM>.

Additionally, in some embodiments, the third gear <NUM> can be rotationally coupled to the second gear <NUM>. Accordingly, the third gear <NUM> and second gear <NUM> can cooperate to define a first compound gear <NUM>. Because they are rotationally coupled, the third gear <NUM> can be configured to rotate in synch with the second gear <NUM>. In some embodiments, the third gear <NUM> can be immediately adjacent and fixed to the second gear <NUM>. For example, the third gear <NUM> and second gear <NUM> can be stacked end-to-end and considered "in-series" so that the first compound gear <NUM> is relatively compact.

Additionally, the third gear <NUM> and the second gear <NUM> can have different pitch diameters. It will be appreciated that the pitch diameters are measured along the transverse axis <NUM>. In the embodiments shown, the pitch diameter of the third gear <NUM> can be less than the pitch diameter of the second gear <NUM>. Also, the third gear <NUM> and the second gear <NUM> can have different thicknesses. It will be appreciated that the thicknesses are measured along the longitudinal axis <NUM>. In the embodiments shown, the thickness of the third gear <NUM> can be greater than the thickness of the second gear <NUM>. These dimensional differences between the third gear <NUM> and the second gear <NUM> can ensure that the desired gear ratio/reduction is achieved through the gear train <NUM>.

In some embodiments, the third gear <NUM> and the second gear <NUM> can be welded together, pressed together, keyed together, adhesively fixed, attached by fasteners or otherwise fixed together. In additional embodiments, the third gear <NUM> and the second gear <NUM> can be integrally connected so that the third gear <NUM> and second gear <NUM> define a monolithic, unitary, one-piece gear member <NUM>.

A second compound gear <NUM> includes a fourth gear <NUM>, referred herein as a "ring gear" <NUM>. The ring gear <NUM> includes or is otherwise coupled to a head <NUM>. The head <NUM> can be annular and can have a substantially constant diameter, as measured along its length. The ring gear <NUM> is fixedly secured to a shaft <NUM> proximate a first end <NUM> of the shaft <NUM>. In various examples, the shaft <NUM> is a second intermediate shaft. The shaft <NUM> variously includes as an integral component or is fixedly secured to a fifth gear <NUM> proximate a second end <NUM> of the shaft <NUM>. The fifth gear <NUM> is engaged with a sixth gear <NUM> which rotates about the first intermediate shaft <NUM>. The shaft <NUM> and the fifth gear <NUM> combined are collectively referred herein as an elongate shaft gear <NUM>. The ring gear <NUM> and the elongate shaft gear <NUM> combine to form the second compound gear <NUM>. As such, the ring gear <NUM> and the elongate shaft gear <NUM> are fixed with respect to one another for synchronous rotation.

The components which are fixedly secured with respect to one another can be secured according to any of a variety of modes. In various examples, the ring gear <NUM> and the elongate shaft gear <NUM> are fixedly secured with respect to one another by a press or friction fit. Additionally or alternatively, such individual components can be fixedly secured with respect to one another by welding, a fastener or other securing member, such as a key. Notwithstanding their individually identifiable components, the ring gear <NUM> and the elongate shaft gear <NUM> can be milled, machined, or otherwise formed from a single base material or can be formed as a single piece, e.g., by three-dimensional printing techniques.

The shaft <NUM> is mounted for rotation on a first support member <NUM> and the second support member <NUM>. In an example, the second intermediate shaft <NUM> does not include bore and is instead substantially solid along a length of the shaft. As such, forming a bore can be avoided when manufacturing, which can increase manufacturing efficiency. Additionally, it can be easier to center the ring gear <NUM> and the fifth gear <NUM> about their common axis of rotation because there is no bore that extends through the shaft <NUM>. Moreover, the head <NUM> can have greater wall thickness than can be possible with a bore, potentially making the second intermediate shaft <NUM> stronger for transferring torque from the ring gear <NUM> to the shaft gear <NUM> than alternative shafts.

Because they are rotationally coupled, the fifth gear <NUM> can be configured to rotate in synch with the fourth gear <NUM>. The fifth gear <NUM> and fourth gear <NUM> can be rotationally coupled by assembling multiple parts together. In other embodiments, the fifth gear <NUM> and fourth gear <NUM> can be integrally connected so that the second compound gear <NUM> is monolithic and unitary.

The sixth gear <NUM> can be mounted on the first intermediate shaft <NUM>, proximate the second end <NUM>. In some embodiments, the sixth gear <NUM> can be mounted for rotation relative to the first intermediate shaft <NUM>.

The seventh gear <NUM> can also be mounted on the first intermediate shaft <NUM>, proximate the sixth gear <NUM>. Like the sixth gear <NUM>, the seventh gear <NUM> can be mounted for rotation relative to the first intermediate shaft <NUM>.

Additionally, in some embodiments, the seventh gear <NUM> can be rotationally coupled to the sixth gear <NUM>. Accordingly, the seventh gear <NUM> and sixth gear <NUM> can cooperate to define a third coupled gear member <NUM>. Because they are rotationally coupled, the seventh gear <NUM> can be configured to rotate in synch with the sixth gear <NUM>. The seventh gear <NUM> and sixth gear <NUM> can be rotationally coupled by assembling multiple parts together. In other embodiments, the seventh gear <NUM> and sixth gear <NUM> can be integrally connected so that the third coupled gear member <NUM> is monolithic and unitary.

Furthermore, the eighth gear <NUM> can be mounted on the reel shaft <NUM>, proximate the second end <NUM>. In some embodiments, the eighth gear <NUM> can be mounted for rotation relative to the reel shaft <NUM>. The ninth gear <NUM> can also be mounted on the reel shaft <NUM>, proximate the eighth gear <NUM>. Like the eighth gear <NUM>, the ninth gear <NUM> can be mounted for rotation relative to the reel shaft <NUM>.

Additionally, in some embodiments, the ninth gear <NUM> can be rotationally coupled to the eighth gear <NUM>. Accordingly, the ninth gear <NUM> and eighth gear <NUM> can cooperate to define a fourth coupled gear member <NUM>. Because they are rotationally coupled, the ninth gear <NUM> can be configured to rotate in synch with the eighth gear <NUM>. The ninth gear <NUM> and eighth gear <NUM> can be rotationally coupled by assembling multiple parts together. In other embodiments, the ninth gear <NUM> and eighth gear <NUM> can be integrally connected so that the fourth coupled gear member <NUM> is monolithic and unitary.

Moreover, the tenth gear <NUM> can be mounted on the first intermediate shaft <NUM>, between the first compound gear <NUM> and the third coupled gear member <NUM>. In some embodiments, the tenth gear <NUM> can be mounted for rotation relative to the first intermediate shaft <NUM>.

The eleventh gear <NUM> can also be mounted on the first intermediate shaft <NUM>, proximate the tenth gear <NUM>. Specifically, the eleventh gear <NUM> can be proximate the third gear <NUM> of the first compound gear <NUM>, whereas the tenth gear <NUM> can be proximate the seventh gear <NUM> of the third coupled gear member <NUM>. Like the tenth gear <NUM>, the eleventh gear <NUM> can be mounted for rotation relative to the first intermediate shaft <NUM>.

Additionally, in some embodiments, the eleventh gear <NUM> can be rotationally coupled to the tenth gear <NUM>. Accordingly, the eleventh gear <NUM> and tenth gear <NUM> can cooperate to define a fifth coupled gear member <NUM>. Because they are rotationally coupled, the eleventh gear <NUM> can be configured to rotate in synch with the tenth gear <NUM>. The eleventh gear <NUM> and tenth gear <NUM> can be rotationally coupled by assembling multiple parts together. In other embodiments, the eleventh gear <NUM> and tenth gear <NUM> can be integrally connected so that the fifth coupled gear member <NUM> is monolithic and unitary.

Finally, the twelfth gear <NUM> can be mounted on the reel shaft <NUM>, proximate the first end <NUM>. In some embodiments, the twelfth gear <NUM> can be fixed to rotate in synch with the reel shaft <NUM>.

<FIG> is a depiction of how various gears of the transmission system <NUM> are enmeshed together, in an example embodiment. As illustrated, predetermined pairs of gears within the gear train <NUM> can be enmeshed together. Specifically, the first gear <NUM> can be enmeshed with the second gear <NUM>. Also, the third gear <NUM> can be enmeshed with the fourth gear <NUM>. The fifth gear <NUM> can be enmeshed with the sixth gear <NUM>. The seventh gear <NUM> can be enmeshed with the eighth gear <NUM>. The ninth gear <NUM> can be enmeshed with the tenth gear <NUM>. Finally, the eleventh gear <NUM> can be enmeshed with the twelfth gear <NUM>. Accordingly, torque and power can be transferred from the motor shaft <NUM> to the reel shaft <NUM>. The gear train <NUM> can remain enmeshed, and a separate clutch, brake, or other components can not be needed. Stated differently, the transmission <NUM> can be clutchless and/or brakeless. Moreover, the gear train <NUM> can provide a single, constant gear reduction for the transmission <NUM>.

The first compound gear <NUM> is illustrated schematically via diagonal cross-hatching that is unique to the first compound gear <NUM>. The second compound gear <NUM> is illustrated schematically via a cross-hatching pattern that includes circles. The third coupled gear member <NUM> is illustrated schematically via a cross-hatching pattern that includes rectangles. The fourth coupled gear member <NUM> is illustrated schematically via a cross-hatching pattern that includes asterisks. The fifth coupled gear member <NUM> is illustrated schematically via a cross-hatching pattern that includes "=" symbols.

<FIG> illustrates a torque path <NUM> of the transmission <NUM>, in an example embodiment. The torque path <NUM> can be multidirectional as it extends between the motor shaft <NUM> and the reel shaft <NUM>. For example, in some embodiments, the torque path <NUM> can extend in one direction along the longitudinal axis <NUM> and can later reverse in the opposite direction at least once along the longitudinal axis <NUM>. Likewise, in some embodiments, the torque path <NUM> can extend in one direction along the transverse axis <NUM> and can later reverse in the opposite direction at least once along the transverse axis <NUM>.

In the illustrated embodiment, rotation of the motor shaft <NUM> can rotate the first gear <NUM>. Thus, the first gear <NUM> can be considered the input gear or motor gear that inputs torque to the transmission <NUM>. Also, torque transfer through the transmission <NUM> can rotate the twelfth gear <NUM>, which ultimately rotates the reel <NUM>. Thus, the twelfth gear <NUM> can be considered the output gear or reel gear that outputs torque to the reel <NUM>. The other gears can be considered intermediate gears, which transfer torque from the first gear <NUM> to the twelfth gear <NUM>.

Torque can travel along the torque path <NUM> in the following sequence: from the first gear <NUM>, to the second gear <NUM>, to the third gear <NUM>, to the fourth gear <NUM>, to the fifth gear <NUM>, to the sixth gear <NUM>, to the seventh gear <NUM>, to the eighth gear <NUM>, to the ninth gear <NUM>, to the tenth gear <NUM>, to the eleventh gear <NUM>, and finally to the twelfth gear <NUM>.

In some embodiments, the torque path <NUM> can change directions multiple times. Also, in some embodiments, the torque path <NUM> can reverse directions. For example, a portion of the torque path <NUM> can extend in one direction along the longitudinal axis <NUM>, and another portion of the torque path <NUM> can extend in the opposite direction along the longitudinal axis <NUM>. Additionally, a portion of the torque path <NUM> can extend in one direction along the transverse axis <NUM>, and another portion of the torque path <NUM> can extend in the opposite direction along the transverse axis <NUM>. This can allow the transmission <NUM> to be more compact. Additionally, in some embodiments, the torque path <NUM> can extend in a serpentine fashion through the transmission <NUM>. For example, the torque path <NUM> can alternate and reverse directions along the transverse axis <NUM> as the torque path <NUM> advances along the longitudinal axis <NUM>.

For reference purposes, positive and negative directions are indicated on the longitudinal axis <NUM> and the transverse axis <NUM>. Additionally, for purposes of discussion, the torque path <NUM> is subdivided into a plurality of segments.

As shown, a first segment <NUM> of the torque path <NUM> can extend from the first gear <NUM> to the second gear <NUM>. As such, the first segment can extend in the positive direction along the transverse axis <NUM>. Also, a second segment <NUM> of the torque path <NUM> can extend from the second gear <NUM> to the third gear <NUM>, and the second segment <NUM> can extend in the negative direction along the longitudinal axis <NUM>. Then, a third segment <NUM> can extend from the third gear <NUM> to the fourth gear <NUM> and also in the negative direction along the transverse axis <NUM>. Additionally, a fourth segment <NUM> can extend in the negative direction along the longitudinal axis <NUM> as the fourth segment <NUM> extends from the fourth gear <NUM> to the fifth gear <NUM>. Then, a fifth segment <NUM> can extend in the positive direction along the transverse axis <NUM> as the fifth segment <NUM> extends from the fifth gear <NUM> to the sixth gear <NUM>. Additionally, a sixth segment <NUM> of the torque path <NUM> can extend in the positive direction along the longitudinal axis <NUM> as the sixth segment <NUM> extends from the sixth gear <NUM> to the seventh gear <NUM>. Furthermore, a seventh segment <NUM> can extend in the positive direction along the transverse axis <NUM> as the seventh segment <NUM> extends from the seventh gear <NUM> to the eighth gear <NUM>. Also, an eighth segment <NUM> can extend in the positive direction along the longitudinal axis <NUM> as the eighth segment <NUM> extends from the eighth gear <NUM> to the ninth gear <NUM>. Then, a ninth segment <NUM> of the torque path <NUM> can extend in the negative direction along the transverse axis <NUM> as it extends from the ninth gear <NUM> to the tenth gear <NUM>. Also, a tenth segment <NUM> can extend in the positive direction along the longitudinal axis <NUM> as the tenth segment <NUM> extends from the tenth gear <NUM> to the eleventh gear <NUM>. Finally, an eleventh segment <NUM> of the torque path <NUM> can extend in the positive direction along the transverse axis <NUM> as the eleventh segment <NUM> extends from the eleventh gear <NUM> to the twelfth gear <NUM>.

Thus, in the illustrated embodiment, the direction of the first segment <NUM> of the torque path <NUM> can be opposite the direction of the third segment <NUM>. Likewise, the direction of the third segment <NUM> can be opposite the direction of the fifth segment <NUM>. Moreover, the direction of the fourth segment <NUM> can be opposite the direction of the sixth segment <NUM>. Additional segments are opposite each other as well. Moreover, the sixth segment <NUM>, seventh segment <NUM>, eighth segment <NUM>, ninth segment <NUM>, tenth segment <NUM>, and eleventh segment <NUM> can extend in a serpentine fashion-back and forth along the transverse axis <NUM> as torque is transferred along the longitudinal axis <NUM>.

Because the torque path <NUM> changes direction so many times, a relatively large number of gears can be included within the gear train <NUM>, and yet the transmission <NUM> can be relatively compact. Also, with the high number of gears included in the gear train <NUM>, the gear train <NUM> can collectively achieve a very high gear ratio. As such, the rotational speed of the motor shaft <NUM> can be reduced while torque is increased along the torque path <NUM>. In some embodiments, the gear ratio can be at least <NUM>:<NUM>. In additional embodiments, the gear ratio can be at least <NUM>:<NUM>. In still additional embodiments, the gear ratio can be at least <NUM>:<NUM>. In one embodiment, the gear ratio can be approximately <NUM>:<NUM>.

In the illustrated example, the gear ratio from the first gear <NUM> to the second gear <NUM> is approximately <NUM>:<NUM>. The gear ratio from the third gear <NUM> to the fourth gear <NUM> is approximately <NUM>:<NUM>. Also, the gear ratio from the fifth gear <NUM> to the sixth gear <NUM> is approximately <NUM>:<NUM>. Moreover, the gear ratio from the seventh gear <NUM> to the eighth gear <NUM> is approximately <NUM>:<NUM>. Furthermore, the gear ratio from the ninth gear <NUM> to the tenth gear <NUM> is approximately <NUM>:<NUM>. Finally, the gear ratio from the eleventh gear <NUM> to the twelfth gear <NUM> is approximately <NUM>:<NUM>. Collectively, the gear train <NUM> can provide a gear ratio from the first gear <NUM> to the twelfth gear <NUM> at approximately <NUM>:<NUM>.

With such a gear ratio, the tensioning system <NUM> can provide relatively strong and reliable winding torque to the reel <NUM>, providing for the tensioning member <NUM> to tighten the securement system <NUM> and secure the footwear <NUM> to the wearer's foot. Also, when the footwear <NUM> is secured to the foot, the wearer's jumping, running, or other activities can pull the tensioning member <NUM> away from the reel <NUM>. However, the high gear ratio provided by the gear train <NUM> can provide a mechanical advantage for resisting these forces. Thus, once the tensioning member <NUM> is spooled on the reel <NUM>, the transmission <NUM> can retain the tensioning member <NUM> in the spooled and secured position. It will be appreciated that the transmission <NUM> can resist unwinding of the reel <NUM> even without use of a brake. The gears of the gear train <NUM> can remain enmeshed. Thus, a clutch may not be necessary. In other words, a single, consistent gear ratio is provided that is very high. Also, the motor can be OFF and de-energized, and yet the electromagnetic force of the motor <NUM> can be enough to retain the reel <NUM> in position due to the mechanical advantage provided by the high gear ratio of the gear train <NUM>. Frictional forces within the gear train <NUM> can also aid in retaining the reel <NUM> in position.

If the wearer does wish to loosen the footwear <NUM> from the foot, the wearer can energize the motor <NUM> in the opposite direction. The motor shaft <NUM> can rotate in the opposite direction, and the transmission <NUM> can transfer power to the reel <NUM>, causing the reel shaft <NUM> to rotate in the opposite direction.

<FIG> is a flowchart for making a tensioning system, in an example embodiment. The flowchart is described with respect to the tensioning system <NUM>, though it is noted that the flowchart may be utilized to make any suitable tensioning system or other structure or apparats.

At <NUM>, a shaft gear comprising an elongate shaft is obtained.

At <NUM>, a ring gear is fixedly coupled to a first end of the shaft gear to form a compound gear. In an example, fixedly coupling the ring gear to the shaft gear is with a press fit. In an example, the ring gear forms a hole and fixedly coupling the ring gear to the shaft gear is press fitting the shaft gear inside the hole.

At <NUM>, a transmission is formed with the compound gear, in part by securing the shaft gear to rotate independent of a fixed reference, the elongate shaft substantially parallel to a longitudinal axis of the transmission. The fixed reference is a support member and wherein forming the transmission comprises seating a second end of the shaft gear opposite the first end in the support member. In an example, forming the transmission includes mounting an intermediate gear on an intermediate shaft and seating the intermediate shaft in the support member and parallel to the shaft gear and offset with respect to the shaft gear along the lateral axis. In an example, forming the transmission further comprises seating the reel shaft in the support member. In an example, the ring gear forms a hole, wherein the support member is a first support member and wherein forming the transmission further comprises seating a second support member in part within the hole proximate the first end of the shaft gear.

At <NUM>, a motor shaft of a motor is coupled to the transmission, the elongate shaft offset with respect to the motor shaft along a later al axis.

Claim 1:
A tensioning system (<NUM>) for adjusting a tensioning member (<NUM>) of an article of footwear comprising:
a reel (<NUM>) configured to spool the tensioning member, the reel comprising a reel shaft (<NUM>);
a motor (<NUM>) comprising a motor shaft (<NUM>), the motor shaft and the reel shaft being substantially parallel to a longitudinal axis, the motor shaft being spaced apart from the reel shaft along a lateral axis; and
a transmission (<NUM>) configured to transmit torque from the motor shaft to the reel shaft along a torque path to drive and rotate the reel shaft, the transmission comprising:
a compound gear (<NUM>), comprising:
a shaft gear (<NUM>), comprising an elongate shaft substantially parallel to the longitudinal axis and offset with respect to the motor shaft along the lateral axis, the shaft gear configured to rotate independent of a fixed reference, and operatively coupled the reel, wherein the fixed reference is a support member (<NUM>) and wherein a second end of the shaft gear (<NUM>) opposite the first end is seated in the support member; and
a ring gear (<NUM>), fixedly coupled to a first end of the shaft gear and operatively coupled to the motor.