Patent Description:
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.

<CIT> describes systems and apparatus related to footwear. In particular, a modular footwear apparatus including an upper portion, a lower portion, and a lacing engine is described. The upper portion includes a lace to adjust fit of the upper portion against a foot, the lace being adjustable between a first position and a second position based at least in part on manipulation of an effective length of the lace. The lower portion includes a mid-sole and an out-sole, and the lower portion can be coupled to the upper portion at the mid-sole. The lacing engine includes a top-loading lace spool to engage a loop of the lace to enable manipulation of the effective length of the lace through rotation of the lace spool. The lacing engine is received within a cavity in the lower portion.

<CIT> describes an optical encoder system which includes a module having a light emitting element and a light detecting element. The light detecting element is operable to detect light at a wavelength emitted by the light emitting element. The optical encoder system also includes a code wheel that has facets on its surface. The code wheel can be disposed with respect to the module so that at least some light emitted by the light emitting element is reflected by the facets back toward the module, wherein an amount of reflected light detected by the light detecting element in the module depends at least in part on the rotational position of the code wheel.

The invention relates to a motorized lacing system as specified in appended independent claim <NUM> and to a method 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 a rotary drum encoder. 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.

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, including the lacing engine <NUM>, the mid-sole plate <NUM>, and the underlying footwear <NUM>. The system <NUM> as illustrated includes interface buttons <NUM>, interface button actuators <NUM>, a foot presence sensor <NUM>, and the lacing engine housing <NUM> enclosing a main PCB <NUM> and a user interface PCB <NUM>. The user interface PCB <NUM> includes the buttons <NUM>, one or more light emitting diodes (LEDs) <NUM> which may illuminate the button actuators <NUM> or otherwise provide illumination visible outside of the article of footwear, an optical encoder <NUM>, and an LED driver <NUM> which may provide power to the LEDs <NUM>. The main PCB <NUM> includes a processor circuit <NUM>, an electronic data storage <NUM>, a battery charging circuit <NUM>, a wireless transceiver <NUM>, one or more sensors <NUM>, such as accelerometers, gyroscopes, and the like, and a motor driver <NUM>.

The lacing engine <NUM> further includes a foot presence sensor <NUM>, such as a capacitive sensor, a motor <NUM>, a transmission <NUM>, a spool <NUM>, a battery or power source <NUM>, and a charging coil <NUM>. The processor circuit <NUM> is configured with instructions from the electronic data storage <NUM> to cause motor driver <NUM> to activate the motor <NUM> to turn the spool <NUM> by way of the transmission <NUM> in order to place a desired amount of tension on a lace <NUM> wound about the spool <NUM>. The processor circuit <NUM> may receive inputs from a variety of sources, including the foot presence sensor <NUM>, the sensors <NUM>, and the buttons <NUM>, to decide, according to the instructions, to increase or decrease the tension on the lace <NUM>. For instance, the foot presence sensor <NUM> may detect the presence of a foot in the footwear <NUM>, and the processor circuit <NUM> may set the tension to a present tension level. The sensors <NUM> may detect movement consistent with a particular activity level, e.g., causal walking, a vigorous physical activity, etc., and the processor circuit <NUM> may cause the tension to be set to a level consistent with that activity level, e.g., relatively loose for casual walking and relatively tight for vigorous physical activity. A user may press the button actuators <NUM> to manually command an incremental or linear increase or decrease in tension as desired.

The battery <NUM> provides power for the components of the lacing engine <NUM> in general and is, in the example embodiment, a rechargeable battery. However, alternative power sources, such as non-rechargeable batteries, super capacitors, and the like, are also contemplated. In the illustrated example, the battery <NUM> is coupled to the charging circuit <NUM> and the recharge coil <NUM>. When the recharge coil <NUM> is placed in proximity of an external charger <NUM>, a charging circuit <NUM> may energize a transmit coil <NUM> to inductively induce a current in the recharge coil <NUM>, which is then utilized by the charging circuit <NUM> to recharge the battery <NUM>. Alternative recharging mechanisms are contemplated, such as a piezoelectric generator located within the footwear <NUM>.

The wireless transceiver <NUM> is configured to communicate wirelessly with a remote user device <NUM>, such as a smartphone, wearable device, tablet computer, personal computer, and the like. In example, the wireless transceiver <NUM> is configured to communicate according to the Bluetooth Low Energy modality, though the wireless transceiver <NUM> may communicate according to any suitable wireless modality, including near field communication (NFC), <NUM> WiFi, and the like. Moreover, the wireless transceiver <NUM> may be configured to communicate with multiple external user devices <NUM> and/or according to multiple different wireless modalities. The wireless transceiver <NUM> may receive instructions from the user device <NUM>, e.g., using an application operating on the user device <NUM>, for controlling the lacing engine <NUM>, including to enter pre-determined modes of operation or to incrementally or linearly increase or decrease the tension on the lace <NUM>. The wireless transceiver <NUM> may further transmit information about the lace engine <NUM> to the user device <NUM>, e.g., an amount of tension on the lace <NUM> or otherwise an orientation of the spool <NUM>, an amount of charge remaining on the battery <NUM>, and any other desired information about the lacing engine <NUM> generally.

<FIG> is an exploded view of the lacing engine <NUM>, in an example embodiment. The lacing engine <NUM> includes the housing <NUM>, which includes an upper portion 103A and a lower portion 103B, which enclose the lacing engine <NUM> generally, except for certain components which are exterior of the housing <NUM>. Those components include the button actuators <NUM> (and related O-rings <NUM> for protecting the lacing engine <NUM> against environmental conditions, such as moisture), the spool <NUM>, which is secured to the transmission <NUM> via a setscrew <NUM> and which is enclosed with the lid <NUM>, and a dielectric foam <NUM> of the foot presence sensor <NUM>. Enclosed within the housing <NUM> is the main PCB <NUM>, the user interface PCB <NUM>, the motor <NUM>, the transmission <NUM>, the battery <NUM>, the recharge coil <NUM>, and an electrode <NUM> and foam <NUM> of the foot presence sensor <NUM>.

Partially visible in the exploded view is the optical encoder <NUM>. Specifically, a three-dimensional encoder <NUM> of the optical encoder <NUM> is coupled to the motor <NUM> and turns with the turning of the motor. Specific implementations of the three-dimensional encoder <NUM> are illustrated herein.

<FIG> is a view of the lower portion 103B of the housing <NUM> in relation to the main PCB <NUM>. Included in the lower portion 103B are posts <NUM> extending from in interior surface <NUM> of the lower portion 103B of the housing <NUM>. As will be illustrated herein, at least one of the posts <NUM> extend through a hole in the main PCB <NUM> (not visible). When an external force is placed on the exterior of the lower portion 103B of the housing <NUM>, e.g., because a wearer of the footwear <NUM> steps on an object that imparts force through the mid-sole <NUM> and plate <NUM> (<FIG>), the lower portion 103B may flex. The posts <NUM> are positioned such that the flexing of the lower portion 103B may result in one or more of the posts <NUM> contacting a relatively more solid or resilient component of the lacing engine <NUM>, e.g., the motor <NUM>, the transmission <NUM>, or the battery <NUM>, rather than the a relatively less resilient component, such as the main PCB <NUM>.

<FIG> are sequential block diagrams illustrating the function of a post <NUM> when a force <NUM> is imparted on the lower portion 103B, in an example embodiment. The block diagram has been simplified and exaggerated for the purposes of illustration. It is to be recognized that multiple posts <NUM> may be implemented according to the principles illustrated herein across a variety of locations, as illustrated in <FIG>, and that the posts <NUM> may be positioned and configured to contact any suitable resilient component, as noted herein.

<FIG> shows the lower portion 103B coupled to the upper portion 103A with a post <NUM> projecting from the interior surface <NUM> of the lower portion 103B. The post <NUM> extends through a hole <NUM> formed in the main PCB <NUM>. As illustrated, the post does not contact the transmission <NUM> but rather has a gap <NUM> therebetween. In various examples, the gap <NUM> is less than a gap <NUM> between the main PCB <NUM> and the interior surface <NUM>. However, it is to be recognized that there may not be a gap <NUM> or that the gap <NUM> may be approximately the same as the gap <NUM>. As no force has been imparted on the lower portion 103B, the lower portion 103B is substantially flat and linear.

<FIG> shows the lower portion 103B bowed on account of the force <NUM> imparted on the lower portion 103B. The bowing of the lower portion 103B has caused the post <NUM> to contact the transmission <NUM>, transferring at least some of the force <NUM> to the transmission <NUM>. While the gap <NUM> between the post <NUM> and the transmission <NUM> has been eliminated, at least some gap <NUM> remains between the interior surface <NUM> and the main PCB <NUM>. As a result, in this example, no portion of the force <NUM> is imparted on the relatively fragile main PCB <NUM> and is instead imparted on the more resilient transmission <NUM>.

It is to be recognized and understood that while the exaggerated illustration shows no contact between the lower portion 103B and the main PCB <NUM>, actual implementations may nonetheless result in some contact between the lower portion 103B and the main PCB <NUM>, and/or that at least some of the force <NUM> is imparted on the main PCB <NUM>. However, at minimum, the presence of the post <NUM> may tend to cause at least some of the force <NUM> to be imparted on the transmission <NUM> rather than on to the main PCB <NUM>. A relative reduction in the amount of force <NUM> imparted on the main PCB <NUM> than would be the case without the post <NUM> may still reduce a likelihood of the main PCB <NUM> being damage from imparted force <NUM> on the lower portion 103B.

<FIG> are side and perspective views of the lace engine <NUM>, in an example embodiment. Components such as the main PCB <NUM>, user interface PCB <NUM>, motor <NUM>, transmission <NUM>, battery <NUM>, electrode <NUM>, foam <NUM>, and recharge coil <NUM> are contained within the top portion 103A and bottom portion 103B of the housing <NUM>. The spool <NUM> is secured to the transmission <NUM> via the set screw <NUM>. The top portion 103A generally conforms to a curved contour of the motor <NUM>.

In an example, the top portion 103A and bottom portion 103B are each approximately <NUM> millimeters thick. The recharge coil <NUM> is approximately <NUM> millimeters thick, including a ferrite backing. The battery <NUM> is approximately <NUM> millimeters thick, accounting for a swelling of the battery <NUM> over time. In an example, the electrode <NUM> is approximately <NUM> millimeters thick and the foam <NUM> is approximately <NUM> millimeters thick, providing for a total thickness of the lace engine <NUM> proximate the battery <NUM> of approximately <NUM> millimeters. In an example, the motor <NUM> is approximately <NUM> millimeters thick and the lace engine <NUM> proximate the motor <NUM> has a maximum thickness of approximately <NUM> millimeters. In an example, the lace engine <NUM> proximate the spool <NUM> has a thickens of approximately <NUM> millimeters.

<FIG> is a depiction of a three-dimensional encoder <NUM>, in an example embodiment. The three-dimensional encoder <NUM> may function as the three-dimensional encoder <NUM> in the optical encoder <NUM>. 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., a motor shaft. The securing portion may be solid or may be individual portions that extend between the drum portion <NUM> and the motor, 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 main PCB <NUM> while the second optical sensor <NUM> is positioned on a second major surface <NUM> of the main 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, in an example an alternative example of the optical sensor <NUM> may have only one individual optical sensor, while 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 main 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> may pass is offset by distance relative to the major axis <NUM>. In <FIG>, with the aperture <NUM> fixed about the shaft, 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.

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. 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>.

<FIG> is an illustration of a three-dimensional encoder <NUM>, in an example embodiment. Unlike the three-dimensional encoders <NUM>, <NUM>, the three-dimensional encoder <NUM> utilizes tabs <NUM> and gaps <NUM> to provide surfaces or lack thereof from light is either reflected, in the case of the tabs <NUM>, or not reflected, in the case of the gaps <NUM>. The optical sensors <NUM>, <NUM> detect the light reflected from the tabs <NUM> and not the absence of reflected light when the gaps <NUM> align with the optical sensors <NUM>, <NUM>. In an example, the optical sensor <NUM>, <NUM> form an angle therebetween of approximately fifty-four (<NUM>) degrees. A beam break <NUM> includes slits <NUM> through which light passes to focus the light for the purposes of the focusing the light for detection by the optical sensors <NUM>, <NUM>. The three-dimensional encoder <NUM> is rotationally coupled to the motor <NUM>, as with the other encoders <NUM>, <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 (<NUM>), comprising:
a motor (<NUM>);
a spool (<NUM>), coupled to the motor, configured to spool and unspool a lace (<NUM>) based on the turning of the motor;
a processor circuit (<NUM>); and
an optical encoder (<NUM>), comprising:
an encoder (<NUM>) defining a major axis and having a surface having a plurality of tabs (<NUM>);
an optical sensor (<NUM>, <NUM>), positioned within optical range of the encoder, configured to output a signal to the processor circuit indicative of a detected one of the plurality of tabs; and
wherein the processor circuit is configured to operate the motor based, at least in part, on the signal as received from the optical sensor.