Patent Description:
<CIT> discloses an item of footwear comprising a shoe with a sole and an upper provided with at least one flexible part, said item of footwear comprising a tying system designed to facilitate the tying and untying of said flexible part on a foot placed in the shoe, in which the tying system comprises a source of electrical energy, motorized drive means powered by the source of electrical energy, and tying means connected to the drive means and to said flexible part in such a way as to allow said flexible part to be tied or untied around the foot.

The following specification describes various aspects of a footwear assembly involving a lacing system including a motorized or non-motorized lacing engine, footwear components related to the lacing engines, automated lacing footwear platforms, and related manufacturing processes. More specifically, much of the following specification describes various aspects of lacing architectures (configurations) for use in footwear including motorized or non-motorized lacing engines for centralized lace tightening. The invention is defined in the attached independent claims to which reference should now be made. Further, optional features may be found in the sub-claims appended thereto.

Any headings provided herein are merely for convenience and do not necessarily affect the scope or meaning of the terms used or discussion under the heading.

The concept of self-tightening shoe laces was first widely popularized by the fictitious power-laced Nike® sneakers worn by Marty McFly in the movie Back to the Future II, which was released back in <NUM>. While Nike® has since released at least one version of power-laced sneakers similar in appearance to the movie prop version from Back to the Future II, the internal mechanical systems and surrounding footwear platform employed do not necessarily lend themselves to mass production or daily use. Additionally, other previous designs for motorized lacing systems comparatively suffered from problems such as high cost of manufacture, complexity, assembly challenges, and poor serviceability. The present inventors have developed a modular footwear platform to accommodate motorized and non-motorized lacing engines that solves some or all of the problems discussed above, among others. In order to fully leverage the modular lacing engine discussed briefly below and in greater detail in co-pending Application Serial Number <CIT>, titled "LACING APPARATUS FOR AUTOMATED FOORWEAR PLATFORM," the present inventors developed a lacing architectures discussed herein. The lacing architectures discussed herein can solve various problems experienced with centralized lace tightening mechanisms, such as uneven tightening, fit, comfort, and performance. The lacing architectures provide various benefits, including smoothing out lace tension across a greater lace travel distance and enhanced comfort while maintaining fit performance. One aspect of enhanced comfort involves a lacing architecture that reduces pressure across the top of the foot. Example lacing architectures can also enhance fit and performance by manipulating lace tension both a medial-lateral direction as well as in an anterior-posterior (front to back) direction. Various other benefits of the components described below will be evident to persons of skill in the relevant arts.

The lacing architectures discussed were developed specifically to interface with a modular lacing engine positioned within a mid-sole portion of a footwear assembly. However, the concepts could also be applied to motorized and manual lacing mechanisms disposed in various locations around the footwear, such as in the heel or even the toe portion of the footwear platform. The lacing architectures discussed include use of lace guides that can be formed from tubular plastic, metal clip, fabric loops or channels, plastic clips, and open u-shaped channels, among other shapes and materials. In some examples, various different types of lacing guides can be mixed to perform specific lace routing functions within the lacing architecture.

The motorized lacing engine discussed below was developed from the ground up to provide a robust, serviceable, and inter-changeable component of an automated lacing footwear platform. The lacing engine includes unique design elements that enable retail-level final assembly into a modular footwear platform. The lacing engine design allows for the majority of the footwear assembly process to leverage known assembly technologies, with unique adaptions to standard assembly processes still being able to leverage current assembly resources.

In an example, the modular automated lacing footwear platform includes a mid-sole plate secured to the mid-sole for receiving a lacing engine. The design of the mid-sole plate allows a lacing engine to be dropped into the footwear platform as late as at a point of purchase. The mid-sole plate, and other aspects of the modular automated footwear platform, allow for different types of lacing engines to be used interchangeably. For example, the motorized lacing engine discussed below could be changed out for a human-powered lacing engine. Alternatively, a fully automatic motorized lacing engine with foot presence sensing or other optional features could be accommodated within the standard mid-sole plate.

Utilizing motorized or non-motorized centralized lacing engines to tighten athletic footwear presents some challenges in providing sufficient performance without sacrificing some amount of comfort. Lacing architectures discussed herein have been designed specifically for use with centralized lacing engines, and are designed to enable various footwear designs from casual to high-performance.

This initial overview is intended to introduce the subject matter of the present patent application. It is not intended to provide an exclusive or exhaustive explanation of the various inventions disclosed in the following more detailed description.

The following discusses various components of the automated footwear platform including a motorized lacing engine, a mid-sole plate, and various other components of the platform. While much of this disclosure focuses on lacing architectures for use with a motorized lacing engine, the discussed designs are applicable to a human-powered lacing engine or other motorized lacing engines with additional or fewer capabilities. Accordingly, the term "automated" as used in "automated footwear platform" is not intended to only cover a system that operates without user input. Rather, the term "automated footwear platform" includes various electrically powered and human-power, automatically activated and human activated mechanisms for tightening a lacing or retention system of the footwear.

<FIG> is an exploded view illustration of components of a motorized lacing system for footwear, according to some example embodiments. The motorized lacing system <NUM> illustrated in <FIG> includes a lacing engine <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.

In an example, the footwear article or the motorized lacing system <NUM> includes or is configured to interface with one or more sensors that can monitor or determine a foot presence characteristic. Based on information from one or more foot presence sensors, the footwear including the motorized lacing system <NUM> can be configured to perform various functions. For example, a foot presence sensor can be configured to provide binary information about whether a foot is present or not present in the footwear. If a binary signal from the foot presence sensor indicates that a foot is present, then the motorized lacing system <NUM> can be activated, such as to automatically tighten or relax (i.e., loosen) a footwear lacing cable. In an example, the footwear article includes a processor circuit that can receive or interpret signals from a foot presence sensor. The processor circuit can optionally be embedded in or with the lacing engine <NUM>, such as in a sole of the footwear article.

<FIG> is a top view diagram of upper <NUM> illustrating an example lacing configuration, according to some example embodiments. In this example, the upper <NUM> includes lateral lace fixation <NUM>, medial lace fixation <NUM>, lateral lace guides <NUM>, medial lace guides <NUM>, and brio cables <NUM>, in additional to lace <NUM> and lacing engine <NUM>. The example illustrated in <FIG> includes a continuous knit fabric upper <NUM> with diagonal lacing pattern involving nonoverlapping medial and lateral lacing paths. The lacing paths are created starting at the lateral lace fixation <NUM> running through the lateral lace guides <NUM> through the lacing engine <NUM> up through the medial lace guides <NUM> back to the medial lace fixation <NUM>. In this example, lace <NUM> forms a continuous loop from lateral lace fixation <NUM> to medial lace fixation <NUM>. Medial to lateral tightening is transmitted through brio cables <NUM> in this example. In other examples, the lacing path may crisscross or incorporate additional features to transmit tightening forces in a medial-lateral direction across the upper <NUM>. Additionally, the continuous lace loop concept can be incorporated into a more traditional upper with a central (medial) gap and lace <NUM> crisscrossing back and forth across the central gap.

<FIG> are top-view diagrams illustrating a flattened footwear upper <NUM> with a lacing architecture <NUM> for use in footwear assemblies including a motorized lacing engine, according to some example embodiments. For the purposes of discussing example footwear uppers, the upper <NUM> is assumed to be designed for incorporation into a right foot version of a footwear assembly. <FIG> is a top-view diagram of a flattened footwear upper <NUM> with a lacing architecture <NUM> as illustrated. In this example, footwear upper <NUM> includes a series of lace guides 320A - 320J (collectively referred to as lace guide(s) <NUM>) with a lace cable <NUM> running through the lace guides <NUM>. The lace cable <NUM>, in this example, forms a loop that is terminated on each side of the upper <NUM> at a lateral lace fixation 345A and a medial lace fixation 345B (collectively referred to as lace fixation points <NUM>) with the middle portion of the loop routed through a lacing engine within a mid-sole of the footwear assembly. The upper <NUM> also includes reinforcements associated with each of the series of lace guides <NUM>. The reinforcements can cover individual lace guides or span multiple lace guides. In this example, the reinforcements include a central reinforcement <NUM>, a first lateral reinforcement 335A, a first medial reinforcement 335B, a second lateral reinforcement 330A, a second medial reinforcement 330B. The middle portion of the lace cable <NUM> is routed to and/or from the lacing engine via a lateral rear lace guide 315A and a medial rear lace guide 315B, and exits and/or enters the upper <NUM> through a lateral lace exit 340A and a medial lace exit 340B.

The upper <NUM> can include different portions, such as a forefoot (toe) portion <NUM>, a mid-foot portion <NUM>, and a heel portion <NUM>. The forefoot portion <NUM> corresponding with joints connecting metatarsal bones with phalanx bones of a foot. The mid-foot point <NUM> may correspond with an arch area of the foot. The heel portion <NUM> may correspond with the rear or heel portions of the foot. The medial and lateral sides of the mid-foot portion of the upper <NUM> can include a central portion <NUM>. In some common footwear designs the central portion <NUM> can include an opening spanned by crisscrossing (or similar) pattern of laces that allows for the fit of the footwear upper around the foot to be adjusted. A central portion <NUM> including an opening also facilitates entry and removal of the foot from the footwear assembly.

The lace guides <NUM> are tubular or channel structures to retain the lace cable <NUM>, while routing the lace cable <NUM> through a pattern along each of a lateral side and a medial side of the upper <NUM>. In this example, the lace guides <NUM> are u-shaped plastic tubes laid out in an essentially sinusoidal wave pattern, which cycles up and down along the medial and lateral sides of the upper <NUM>. The number of cycles completed by the lace cable <NUM> may vary depending on shoe size. Smaller sized footwear assemblies may only be able to accommodate one and one half cycles, with the example upper <NUM> accommodating two and one half cycles before entering the medial rear lace guide 315B or the lateral rear lace guide 315A. The pattern is described as essentially sinusoidal, as in this example at least, the u-shape guides have a wider profile than a true sine wave crest or trough. In other examples, a pattern more closely approximating a true sine wave pattern could be utilized (without extensive use of carefully curved lace guides, a true sine wave is not easily attained with a lace stretched between lace guides). The shape of the lace guides <NUM> can be varied to generate different torque versus lace displacement curves, where torque is measured at the lacing engine in the mid-sole of the shoe. Using lace guides with tighter radius curves, or including a higher frequency of wave pattern (e.g., greater number of cycles with more lace guides), can result in a change to the torque versus lace displacement curve. For example, with tighter radius lace guides the lace cable experiences higher friction, which can result in a higher initial torque, which may appear to smooth out the torque out over the torque versus lace displacement curve. However, in certain implementations it may be more desirable to maintain a low initial torque level (e.g., by keep friction within the lace guides low) while utilizing lace guide placement pattern or lace guide design to assist in smoothing the torque versus lace displacement curve. One such lace guide design is discussed in reference to <FIG> and <FIG>, with another alternative lace guide design discussed in reference to <FIG>. In addition to the lace guides discussed in reference to these figures, lace guides can be fabricated from plastics, polymers, metal, or fabric. For example, layers of fabric can be used to create a shaped channel to route a lace cable in a desired pattern. As discussed below, combinations of plastic or metal guides and fabric overlays can be used to generate guide components for use in the discussed lacing architectures.

Returning to <FIG>, the reinforcements <NUM>, <NUM>, and <NUM> are illustrated associated with different lace guides, such as lace guides <NUM>. In an example, the reinforcements <NUM> can include fabric impregnated with a heat activated adhesive that can be adhered over the top of lace guides <NUM>, <NUM>, a process sometimes referred to as hot melt. The reinforcements can cover a number of lace guides, such as reinforcement <NUM>, which in this example covers six upper lace guides positioned adjacent to a central portion of the footwear, such as central portion <NUM>. In another example, the reinforcement <NUM> could be split down the middle of the central portion <NUM> to form two pieces covering lace guides along a medial side of the central portion <NUM> separately from lace guides along a lateral side of the central portion <NUM>. In yet another alternative example, the reinforcement <NUM> could be split into six separate reinforcements covering individual lace guides. Use of reinforcements can vary to change the dynamics of interaction between the lace guides and the underlying footwear upper, such as upper <NUM>. Reinforcements can also be adhered to the upper <NUM> in various other manners, including sewing, adhesives, or a combination of mechanisms. The manner of adhering the reinforcement in conjunction with the type of fabric or materials used for the reinforcements can also impact the friction experienced by the lace cable running through the lace guides. For example, a more rigid material hot melted over otherwise flexible lace guides can increase the friction experienced by the lace cable. In contrast, a flexible material adhered over the lace guides may reduce friction by maintaining more of the lace guide flexibility.

As mentioned above, <FIG> illustrates a central reinforcement <NUM> that is a single member spanning the medial and lateral upper lace guides (320A, 320B, 320E, 320F, 320I, and 320J). Assuming reinforcement <NUM> is more rigid material with less flexibility than the underlying footwear upper, upper <NUM> in this example, the resulting central portion <NUM> of the footwear assembly will exhibit less forgiving fit characteristics. In some applications, a more rigid, less forgiving, central portion <NUM> may be desirable. However, in applications where more flexibility across the central portion <NUM> is desired, the central reinforcement <NUM> can be separated into two or more reinforcements. In certain applications, separated central reinforcements can be coupled across the central portion <NUM> using a variety of flexible or elastic materials to enable a more form fitting central portion <NUM>. In some examples, the upper <NUM> can have a small gap running the length of the central portion <NUM> with one or more elastic members spanning the gap and connecting multiple central reinforcements, such as is at least partially illustrated in <FIG> with lace guide <NUM> and elastic member <NUM>.

<FIG> is another top-view diagram of the flattened footwear upper <NUM> with a lacing architecture <NUM> as illustrated. In this example, footwear upper <NUM> includes a similar lace guide pattern including lace guides <NUM> with modifications to the configuration of reinforcements <NUM>, <NUM>, and <NUM>. As discussed above, the modifications to the reinforcements configuration will result in at least slightly different fit characteristics and may also change the torque versus lace displacement curve.

<FIG> is a series of lacing architecture examples illustrated on flattened footwear uppers according to example embodiments. Lace architecture 300A illustrates a lace guide pattern similar to the sine wave pattern discussed in reference to <FIG> with individual reinforcements covering each individual lace guide. Lace architecture 300B once again illustrates a wave lacing pattern, also referred to as parachute lacing, with elongated reinforcements covering upper lace guide pairs spanning across a central portion and individual lower lace guides. Lace architecture 300C is yet another wave lacing pattern with a single central reinforcement. Lace architecture 300D introduces a triangular shaped lace pattern with individual reinforcements cut to form fit over the individual lace guides. Lace architecture 300E illustrates a variation in reinforcement configuration in the triangular lace pattern. Finally, lace architecture 300F illustrates another variation in reinforcement configuration including a central reinforcement and consolidated lower reinforcements.

<FIG> is a diagram illustrating a portion of a footwear upper <NUM> with a lacing architecture <NUM> for use in footwear assemblies including a motorized lacing engine, according to some example embodiments. In this example, a medial portion of upper <NUM> is illustrated with lace guides <NUM> routing lace cable <NUM> through to medial exit guide <NUM>. Lace guides <NUM> are encapsulated in reinforcements <NUM> to form lace guide components <NUM>, with at least a portion of the lace guide components being repositionable on upper <NUM>. In one example, the lace guide components <NUM> are backed with hook-n-loop material and the upper <NUM> provides a surface receptive to the hook-n-loop material. In this example, the lace guide components <NUM> can be backed with the hook portion with the upper <NUM> providing a knit loop surface to receive the lace guide components <NUM>. In another example, lace guide components <NUM> can have a track interface integrated to engage with a track, such as track <NUM>. A track-based integration can provide a secure, limited travel, movement option for lace guide components <NUM>. For example, track <NUM> runs essentially perpendicular to the longitudinal axis of the central portion <NUM> and allows for positioning a lace guide component <NUM> along the length of the track. In some examples, the track <NUM> can span across from a lateral side to a medial side to hold a lace guide component on either side of central portion <NUM>. Similar tracks can be positioned in appropriate places to hold all of the lace guide components <NUM>, enabling adjustment in restrictions directions for all lace guides on footwear upper <NUM>.

The footwear upper <NUM> illustrates another example lacing architecture including central elastic members, such as elastic member <NUM>. In these examples, at least the upper lace guide components along the medial and lateral sides can be connected across the central portion <NUM> with elastic members that allow for different footwear designs to attain different levels of fit and performance. For example, a high performance basketball shoe that needs to secure a foot through a wide range of lateral movement may utilize elastic members with a high modulus of elasticity to ensure a snug fit. In another example, a running shoe may utilize elastic members with a low modulus of elasticity, as the running shoe may be designed to focus on comfort for long distance road running versus providing high levels of lateral motion containment. In certain examples, the elastic members <NUM> can be interchangeable or include a mechanism to allow for adjustment of the level of elasticity. As discussed above, in some examples the footwear upper, such as upper <NUM>, can include a gap along central portion <NUM> at least partially separating a medial side from a lateral side. Even with a small gap along central portion <NUM> elastic members, such as elastic member <NUM>, can be used to span the gap.

While <FIG> only illustrates a single track <NUM> or a single elastic member <NUM>, these elements can be replicated for any or all of the lace guides in a particular lacing architecture.

<FIG> is a diagram illustrating a portion of footwear upper <NUM> with lacing architecture <NUM> for use in footwear assemblies including a motorized lacing engine, according to some example embodiments. In this example, the central portion <NUM> illustrated in <FIG> is replaced with a central closure mechanism <NUM>, which is illustrated in this example as a central zipper <NUM>. The central closure mechanism is designed to enable a wider opening in the footwear upper <NUM> for easy entry and exit. The central zipper <NUM> can be easily unzipped to enable foot entry or exit. In other examples, the central closure <NUM> can be hook and loop, snaps, clasps, toggles, secondary laces, or any similar closure mechanism.

<FIG> is a diagram illustrating a portion of footwear upper <NUM> with a lacing architecture <NUM> for use in footwear assemblies including a motorized lacing engine, according to some example embodiments. In this example, lacing architecture <NUM> adds a heel lacing component <NUM> including a heel lacing guide <NUM> and a heel reinforcement <NUM> as well as a heel redirect guide <NUM> and a heel exit guide <NUM>. The heel redirect guide <NUM> shifts the lace cable <NUM> from exiting the last lace guide <NUM> towards a heel lacing component <NUM>. The heel lacing component <NUM> is formed from a heel lacing guide <NUM> with a heel reinforcement <NUM>. The heel lacing guide <NUM> is depicted with a similar shape to lacing guides used in other locations on upper <NUM>. However, in other examples the heel lacing guide <NUM> can be other shapes or include multiple lace guides. In this example, the heel lace component <NUM> is shown mounted on a heel track <NUM> allowing for adjustability of the location of the heel lace component <NUM>. Similar to the adjustable lace guides discussed above, other mechanisms can be utilized to enable adjustment in positioning of the heel lace component <NUM>, such as hook and loop fasteners or comparable fastening mechanisms.

In some examples, the upper <NUM> includes a heel ridge <NUM>, which like the central portion <NUM> discussed above can include a closure mechanism. In examples with a heel closure mechanism, the heel closure mechanism is designed to provide easy entry and exit from the footwear by expanding a traditional footwear assembly foot opening. Additionally, in some examples, the heel lacing component <NUM> can be connected across the heel ridge <NUM> (with or without a heel closure mechanism) to a matching heel lacing component on the opposite side. The connection can include an elastic member, similar to elastic member <NUM>.

<FIG> are diagrams illustrating a portion of footwear upper <NUM> with a lacing architecture <NUM> for use in footwear assemblies including a motorized lacing engine, according to some example embodiments. In this example, the lacing architecture <NUM> includes lace guides <NUM> for routing lace <NUM>. The lace guides <NUM> can include associated reinforcements <NUM>. In this example, the lace guides <NUM> are configured to allow for flexing of portions of the lace guides <NUM> from an open initial position illustrated in <FIG> to a flexed closed position illustrated in <FIG> (with phantom lines illustrating the opposition positions in each figure for reference). In this example, the lace guides <NUM> include extension portions that exhibit flex of approximately <NUM> degrees between the open initial position and the closed position. Other examples, can exhibit more or less flex between an initial and final position (or shape) of the lace guide <NUM>. The flexing of the lace guides <NUM> occurs as the lace <NUM> is tightened. The flexing of the lace guides <NUM> works to smooth out the torque versus lace displacement curve by applying some initial tension to the lace <NUM> and providing an additional mechanism to dissipate lace tension during the tightening process. Accordingly, in an initial shape or flex position, lace guide <NUM> creates some initial tension in the lace cable, which also functions to take up slack in the lace cable. When tightening of the lace cable begins, the lace guide <NUM> flexes or deforms.

The lace guides <NUM>, in this example, are plastic or polymer tubes and can have different modulus of elasticity depending upon the particular composition of the tubes. The modulus of elasticity of the lace guides <NUM> along with the configuration of the reinforcements <NUM> will control the amount of additional tension induced in the lace <NUM> by flexing of the lace guides <NUM>. The elastic deformation of the ends (legs or extensions) of the lace guides <NUM> induces a continued tension on the lace <NUM> as the lace guides <NUM> attempt to return to original shape. In some examples, the entire lace guide flexes uniformly over the length of the lace guide. In other examples, the flex occurs primarily within the u-shaped portion of the lace guide with the extensions remaining substantially straight. In yet other examples, the extensions accommodate most of the flex with the u-shaped portion remaining relatively fixed.

The reinforcements <NUM> are adhered over the lace guides <NUM> in a manner that allows for movement of the ends of the lace guides <NUM>. In some examples, reinforcements <NUM> are adhered through the hot melt process discussed above, with the placement of the heat activated adhesive allowing for an opening to enable flex in the lace guides <NUM>. In other embodiments, the reinforcements <NUM> can be sewed into place or use a combination of adhesives and stitching. How the reinforcements <NUM> are adhered or structured can affect what portion of the lace guide flexes under load from the lace cable. In some examples, the hot melt is concentrated around the u-shaped portion of the lace guide leaving the extensions (legs) more free to flex.

<FIG> are diagrams illustrating deformable lace guides <NUM> for use in footwear assemblies, according to some example embodiments. In this example, lace guides <NUM> introduced above in reference to <FIG> and <FIG> are discussed in additional detail. <FIG> illustrates the lace guide <NUM> in a first (open) state, which can be considered a non-deformed state. <FIG> illustrates the lace guide <NUM> in a second (closed/flexed) state, which can be considered a deformed state. The lace guide <NUM> can include three different sections, such as a middle section <NUM>, a first extension <NUM>, and a second extension <NUM>. The lace guide <NUM> can also include a lace reception opening <NUM> and a lace exit opening <NUM>. As mentioned above, lace guide <NUM> can have different modulus of elasticity, which controls the level of deformation with a certain applied tension. In some examples, the lace guide <NUM> can be constructed with different sections having different modulus of elasticity, such as the middle section <NUM> having a first modulus of elasticity, the first extension having a second modulus of elasticity and the second extension having a third modulus of elasticity. In certain examples, the second and third moduli of elasticity can be substantially similar, resulting in the first extension and the second extension flexing or deforming in a similar manner. In this example, substantially similar can be interpreted as the moduli of elasticity being within a few percentage points of each other. In some examples, the lace guide <NUM> can have a variable modulus of elasticity shifting from a high modulus at the apex <NUM> to a low modulus towards the outer ends of the first extension and the second extension. In these examples, the modulus can vary based on wall thickness of the lace guide <NUM>.

The lace guide <NUM> defines a number of axes useful is describing how the deformable lace guide functions. For example, the first extension <NUM> can define an first incoming lace axis <NUM>, which aligns with at least an outer portion of an inner channel defined within the first extension <NUM>. The second extension <NUM> defines an first outgoing lace axis <NUM>, which aligns with at least an outer portion of an inner channel defined within the second extension <NUM>. Upon deformation, the lace guide <NUM> defines a second incoming lace axis <NUM> and a second outgoing lace axis <NUM>, which are each aligned with respective portions of the first extension and the second extension. The lace guide <NUM> also includes a medial axis <NUM> that intersects the lace guide <NUM> at the apex <NUM> and is equidistant from the first extension and the second extension (assuming a symmetrical lace guide in a non-deformed state as illustrated in <FIG>).

<FIG> is a graph <NUM> illustrating various torque versus lace displacement curves for deformable lace guides, according to some example embodiments. As discussed above, one of the benefits achieved using lace guides <NUM> involves modifying torque (or lace tension) versus lace displacement (or shortening) curves. Curve <NUM> illustrates a torque versus displacement curve for a non-deformable lace guide used in an example lacing architecture. The curve <NUM> illustrates how laces experience a rapid increase in tension over a short displacement near the end of the tightening process. In contrast, curve <NUM> illustrates a torque versus displacement curve for a first deformable lace guide used in an example lacing architecture. The cure <NUM> begins in a fashion similar to curve <NUM>, but as the lace guides deform with additional lace tension the curve is flattened, resulting in tension increasing over a larger lace displacement. Flattening out the curves allows for more control of fit and performance of the footwear for the end users.

The final example is split into three segments, an initial tightening segment <NUM>, an adaptive segment <NUM>, and a reactive segment <NUM>. The segments <NUM>, <NUM>, <NUM> may be utilized in any circumstance where the torque and resultant displacement is desired. However, the reactive segment <NUM> may particularly be utilized in circumstances where the motorized lacing engine makes sudden changes or corrections in the displacement of the lace in reaction to unanticipated external factors, e.g., the wearer has abruptly stopped moving, resulting in a relatively high load on the lace. The adaptive segment <NUM>, by contrast, may be utilized when more gradual displacement of the lace may be utilized because a change in the load on the lace may be anticipated, e.g., because the change in load may be less sudden or a change in activity is input into the motorized lacing engine by the wearer or the motorized lacing engine is able to anticipate a change in activity through machine learning. The deformable lace guide design resulting in this final example, is designed to create the adaptive segment <NUM> and reactive segment <NUM> through lace guide structural design (such as channel shape, material selection, or a combination parameters). The lacing architecture and lace guides producing the final example, also produce a pre-tension in the lace cable resulting in the illustrated initial tightening segment <NUM>.

<FIG> are diagrams illustrating an example lacing guide <NUM> for use in certain lacing architectures, according to some example embodiments. In this example, an alternative lace guide with an open lace channel is illustrated. The lacing guide <NUM> described below can be substituted into any of the lacing architectures discussed above in reference to lace guide <NUM>, heel lace guide <NUM>, or even the medial exit guide <NUM>. All of the various configurations discussed above will not be repeated here for the sake of brevity. The lacing guide <NUM> includes a guide tab <NUM>, a stitch opening <NUM>, a guide superior surface <NUM>, a lace retainer <NUM>, a lace channel <NUM>, a channel radius <NUM>, a lace access opening <NUM>, a guide inferior surface <NUM>, and a guide radius <NUM>. Advantages of an open channel lace guide, such as lacing guide <NUM>, include the ability to easily route the lace cable after installation of the lace guides on the footwear upper. With tubular lace guides as illustrated in many of the lace architecture examples discussed above, routing the lace cable through the lace guides is most easily accomplish before adhering the lace guides to the footwear upper (not to say it cannot be accomplished later). Open channel lace guides facilitate simple lace routing by allowing the lace cable to simply be pushed pass the lace retainer <NUM> after the lace guides <NUM> are positioned on the footwear upper. The lacing guide <NUM> can be fabricated from various materials including metal or plastics.

In this example, the lacing guide <NUM> can be initially attached to a footwear upper through stitching or adhesives. The illustrated design includes a stitch opening <NUM> that is configured to enable easy manual or automated stitching of lacing guide <NUM> onto a footwear upper (or similar material). Once lacing guide <NUM> is attached to the footwear upper, lace cable can be routed by simply pulling a loop of lace cable into the lace channel <NUM>. The lace access opening <NUM> extends through the inferior surface <NUM> to provide a relief recess for the lace cable to get around the lace retainer <NUM>. In some examples, the lace retainer <NUM> can be different dimensions or even be split into multiple smaller protrusions. In an example, the lace retainer <NUM> can be narrower in width, but extend further towards or even into access opening <NUM>. In some examples, the access opening <NUM> can also be different dimensions, and will usually somewhat mirror the shape of lace retainer <NUM> (as illustrated in <FIG>). In this example, the channel radius <NUM> is designed to correspond to, or be slightly larger then, the diameter of the lace cable. The channel radius <NUM> is one of the parameters of the lacing guide <NUM> that can control the amount of friction experienced by the lace cable running through the lacing guide <NUM>. Another parameter of lacing guide <NUM> that impacts friction experienced by the lace cable includes guide radius <NUM>. The guide radius <NUM> also may impact the frequency or spacing of lace guides positioned on a footwear upper.

<FIG> is a diagram illustrating a portion of footwear upper <NUM> with a lacing architecture <NUM> using lacing guides <NUM>, according to some example embodiments. In this example, multiple lacing guides <NUM> are arranged on a lateral side of footwear upper <NUM> to form half of the lacing architecture <NUM>. Similar to lacing architectures discussed above, lacing architecture <NUM> uses lacing guides <NUM> to form a wave pattern or parachute lacing pattern to route the lace cable. One of the benefits of this type of lacing architecture is that lace tightening can produce both later-medial tightening as well as anterior-posterior tightening of the footwear upper <NUM>.

In this example, lacing guides <NUM> are at least initially adhered to upper <NUM> through stitching <NUM>. The stitching <NUM> is shown over or engaging stitch opening <NUM>. One of the lacing guide <NUM> is also depicted with a reinforcement <NUM> covering the lacing guide. Such reinforcements can be positioned individually over each of the lacing guides <NUM>. Alternatively, larger reinforcements could be used to cover multiple lacing guides. Similar to the reinforcements discussed above, reinforcement <NUM> can be adhered through adhesives, heat-activated adhesives, and/or stitching. In some examples, reinforcement <NUM> can be adhered using adhesives (heat-activated or not) and a vacuum bagging process that uniformly compresses the reinforcement over the lacing guide. A similar vacuum bagging process can also be used with reinforcements and lacing guides discussed above. In other examples, mechanical presses or similar machines can be used to assist with adhering reinforcements over lacing guides.

Once all of the lacing guides <NUM> are initially positioned and attached to footwear upper <NUM>, the lace cable can be routed through the lacing guides. Lace cable routing can begin with anchoring a first end of the lace cable at lateral anchor point <NUM>. The lace cable can then be pulled into each lace channel <NUM> starting with the anterior most lacing guide and working posteriorly towards the heel of upper <NUM>. Once the lace cable is routed through all lacing guides <NUM>, reinforcements <NUM> can be optionally adhered over each of the lacing guides <NUM> to secure both the lacing guides and the lace cable.

<FIG> is a flowchart illustrating a footwear assembly process <NUM> for assembly of footwear including a lacing engine, according to some example embodiments. In this example, the assembly process <NUM> includes operations such as: obtaining footwear upper, lace guides, and lace cable at <NUM>; routing lace cable through tubular lace guides at <NUM>; anchoring a first end of the lace cable at <NUM>; anchoring a second end of lace cable at <NUM>; positioning lace guides at <NUM>; securing lace guides at <NUM>; and integrating upper with footwear assembly at <NUM>. The process <NUM> described in further detail below can include some or all of the process operations described and at least some of the process operations can occur at various locations and/or using different automated tools.

In this example, the process <NUM> begins at <NUM> by obtaining a footwear upper, a plurality of lace guides, and a lace cable. The footwear upper, such as upper <NUM>, can be a flattened footwear upper separated from the remainder of a footwear assembly (e.g., sole, mid-sole, outer cover, etc.. The lace guides in this example include tubular plastic lace guides as discussed above, but could also include other types of lace guides. At <NUM>, the process <NUM> continues with the lace cable being routed (or threaded) through the plurality of lace guides. While the lace cable can be routed through the lace guides at a different point in the assembly process <NUM>, when using tubular lace guides routing the lace through the lace guides prior to assembly onto the footwear upper may be preferable. In some examples, the lace guides can be pre-threaded onto the lace cable, with process <NUM> beginning with multiple lace guides already threaded onto the lace obtained during the operation at <NUM>.

At <NUM>, the process <NUM> continues with a first end of the lace cable being anchored to the footwear upper. For example, lace cable <NUM> can be anchored along a lateral edge of upper <NUM>. In some examples, the lace cable may be temporary anchored to the upper <NUM> with a more permanent anchor accomplished during integration of the footwear upper with the remaining footwear assembly. At <NUM>, the process <NUM> can continue with a second end of the lace cable being anchored to the footwear upper. Like the first end of the lace cable, the second end can be temporarily anchored to the upper. Additionally, the process <NUM> can optionally delay anchoring of the second end until later in the process or during integration with the footwear assembly.

At <NUM>, the process <NUM> continues with the plurality of lace guides being positioned on the upper. For example, lace guides <NUM> can be positioned on upper <NUM> to generate the desired lacing pattern. Once the lace guides are positioned, the process <NUM> can continue at <NUM> by securing the lace guides onto the footwear upper. For example, the reinforcements <NUM> can be secured over lace guides <NUM> to hold them in position. Finally, the process <NUM> can complete at <NUM> with the footwear upper being integrated into the remainder of the footwear assembly, including the sole. In an example, integration can include positioning the loop of lace cable connecting the lateral and medial sides of the footwear upper in position to engage a lacing engine in a mid-sole of the footwear assembly.

<FIG> is a flowchart illustrating a footwear assembly process <NUM> for assembly of footwear including a plurality of lacing guides, according to some example embodiments. In this example, the assembly process <NUM> includes operations such as: obtaining footwear upper, lace guides, and lace cable at <NUM>; securing lacing guides on footwear upper at <NUM>; anchoring a first end of the lace cable at <NUM>; routing lace cable through the lace guides at <NUM>; anchoring a second end of lace cable at <NUM>; optionally securing reinforcements over the lace guides at <NUM>; and integrating upper with footwear assembly at <NUM>. The process <NUM> described in further detail below can include some or all of the process operations described and at least some of the process operations can occur at various locations and/or using different automated tools.

In this example, the process <NUM> begins at <NUM> by obtaining a footwear upper, a plurality of lace guides, and a lace cable. The footwear upper, such as upper <NUM>, can be a flattened footwear upper separated from the remainder of a footwear assembly (e.g., sole, mid-sole, outer cover, etc.. The lace guides in this example include open channel plastic lacing guides as discussed above, but could also include other types of lace guides. At <NUM>, the process <NUM> continues with the lacing guides being secured to the upper. For example, lacing guides <NUM> can be individually stitched in position on upper <NUM>.

At <NUM>, the process <NUM> continues with a first end of the lace cable being anchored to the footwear upper. For example, lace cable <NUM> can be anchored along a lateral edge of upper <NUM>. In some examples, the lace cable may be temporary anchored to the upper <NUM> with a more permanent anchor accomplished during integration of the footwear upper with the remaining footwear assembly. At <NUM>, the process <NUM> continues with the lace cable being routed through the open channel lace guides, which includes leaving a lace loop for engagement with a lacing engine between the lateral and medial sides of the footwear upper. The lace loop can be a predetermined length to ensure the lacing engine is able to properly tighten the assembled footwear.

At <NUM>, the process <NUM> can continue with a second end of the lace cable being anchored to the footwear upper. Like the first end of the lace cable, the second end can be temporarily anchored to the upper. Additionally, the process <NUM> can optionally delay anchoring of the second end until later in the process or during integration with the footwear assembly. In certain examples, delaying anchoring of the first and/or second end of the lace cable can allow for adjustment in overall lace length, which may be useful during integration of the lacing engine.

At <NUM>, the process <NUM> can optionally include an operation for securing fabric reinforcements (covers) over the lace guides to further secure them to the footwear upper. For example, lacing guides <NUM> can have reinforcements <NUM> hot melted over the lacing guides to further secure the lacing guides and the lace cable. Finally, the process <NUM> can complete at <NUM> with the footwear upper being integrated into the remainder of the footwear assembly, including the sole. In an example, integration can include positioning the loop of lace cable connecting the lateral and medial sides of the footwear upper in position to engage a lacing engine in a mid-sole of the footwear assembly.

The present inventors have recognized, among other things, a need for an improved lacing architecture for automated and semi-automated tightening of shoe laces. This document describes, among other things, example lacing architectures, example lace guides used in the lacing architectures, and related assembly techniques for automated footwear platforms.

Claim 1:
A footwear assembly comprising:
a footwear upper (<NUM>, <NUM>, <NUM>) including a toe box portion, a medial side, a lateral side, a central portion (<NUM>), and a heel portion (<NUM>), the medial side and the lateral side each extending proximally from the toe box portion to a heel portion (<NUM>) on either side of the central portion (<NUM>);
a lace cable (<NUM>) with a first end anchored along a distal outside portion of the medial side and a second end anchored along a distal outside portion of the lateral side;
a plurality of lace guides (<NUM>) distributed along the medial side and the lateral side, each lace guide (<NUM>) of the plurality of lace guides (<NUM>) adapted to receive a length of the lace cable (<NUM>), wherein the lace cable (<NUM>) extends through each of the plurality of lace guides (<NUM>) to form a pattern along each of the medial side and the lateral side of the footwear upper (<NUM>, <NUM>, <NUM>), without crossing over the central portion (<NUM>); and
a reinforcement member (<NUM>) coupling at least one medial side lace guide (<NUM>) with a corresponding lateral side lace guide (<NUM>) across the central portion (<NUM>).