Patent ID: 12225982

DETAILED DESCRIPTION

The present disclosure relates to reel devices and related systems and methods. The reel devices can include an automatic shift assembly that can shift to provide a mechanical advantage when used to tighten a cord. The reel devices can be used in various applications, such as with prosthetic devices. For instance, a prosthetic device can include a cord configured to be tightened to provide a better fit of a prosthesis socket to a user's residuum. Use of the reel devices to tighten cords and/or straps on other types of equipment (e.g., outdoor or sports equipment) is also contemplated. Tightening of the cord may be accomplished using a reel device disclosed herein that can shift to provide a mechanical advantage such that the cord can be easily, quickly, and adequately tightened by hand or by a motor.

The reel device may include a drive assembly and a shift assembly. In one embodiment, the drive assembly may include a drive axle to rotate one or more components, such as a gear assembly and/or a spool. The drive assembly can also include a clutch to limit the maximum amount of tension that can be applied by the reel device. The shift assembly can be automatic. The shift assembly may include one or more of a base, a shift member, or a torque control member. The drive assembly (or components thereof) and the shift assembly (or components thereof) may be modular such that a first drive assembly (or components thereof) having a first drive ratio may be replaced by a second drive assembly (or components thereof) having a second drive ratio, etc.

In another embodiment, the drive assembly may include one or more of a drive axle to rotate one or more components, such as a rotational engagement member, a release disk, a lower cap, a pin gear, a cycloidal gear, an outer gear, and a spool. The drive axle may engage with an upper cap to rotate the drive axle. The rotational engagement member, release disk, lower cap, pin gear, cycloidal gear, and outer gear may be disposed within a cavity of the upper cap. The shift assembly may include one or more of a base, a shift member, or a torque control member. In some of such embodiments, the drive assembly and the shift assembly may be modular such that a first drive assembly having a first drive ratio may be replaced by a second drive assembly having a second drive ratio, etc.

In another embodiment, the drive assembly may include a drive axle to rotate one or more components, such as a lower cap, a pin gear, a cycloidal gear, an outer gear, or a spool. The drive axle may engage with an upper cap to rotate the drive axle. The drive assembly can also include a clutch to limit the maximum amount of tension that can be applied by the reel device. The shift assembly may include one or more of a base, a shift member, or a torque control member. The drive assembly (or components thereof) and the shift assembly (or components thereof) may be modular such that a first drive assembly (or components thereof) having a first drive ratio may be replaced by a second drive assembly (or components thereof) having a second drive ratio, etc.

As detailed below, the reel device is configured to automatically provide a mechanical advantage when tightening the cord of a device. For example, in a pre-shifted (or non-shifted) configuration, the upper cap of the reel device may be rotated such that the spool that uptakes the cord is rotated in a 1:1 ratio (or an approximately 1:1 ratio that is less than about 2:1 or less than about 1.5:1). In other words, for every full turn of the upper cap, the spool is also rotated approximately one full turn. This configuration facilitates a quick uptake of slack of the cord as the upper cap is rotated. As a tension force on the cord increases, the cord can exert a torque force on the shift member, rotating the shift member towards a shifted position. When a threshold tension and/or torque force is exceeded and the shift member has rotated to the shifted position, the reel device changes from the pre or non-shifted configuration having 1:1 drive ratio (or an approximately 1:1 drive ratio) to a shifted configuration having a different drive ratio that provides a mechanical advantage for continued tightening of the cord. This mechanical advantage can decrease the amount of rotational force that is required from the user to continue tightening the cord as the spool is no longer rotated with the upper cap in a 1:1 ratio (or an approximately 1:1 drive ratio). If the tension force on the cord is later decreased below the threshold tension, the reel device can automatically change from the shifted configuration back to the pre or non-shifted configuration having a 1:1 drive ratio (or an approximately 1:1 drive ratio). Configuring the reel device in this manner is advantageous in many ways. For instance, devices that are geared with a constant 1:1 drive ratio (or an approximately 1:1 drive ratio) can be difficult to tighten as the tension on the cord increases, requiring significant amounts of rotational force to be applied by the user. And devices that are geared with a constant mechanical advantage are also disadvantageous, as the speed of adjustment is adversely impacted due to the number of turns that may be required to wind up the cord (especially when there is slack in the cord). The reel devices disclosed herein address these and many other issues, as further discussed below.

Embodiments may be understood by reference to the drawings, wherein like parts are designated by like numerals throughout. It will be readily understood by one of ordinary skill in the art having the benefit of this disclosure that the components of the embodiments, as generally described and illustrated in the figures herein, could be arranged and designed in a wide variety of different configurations. Thus, the following more detailed description of various embodiments, as represented in the figures, is not intended to limit the scope of the disclosure, but is merely representative of various embodiments. While the various aspects of the embodiments are presented in drawings, the drawings are not necessarily drawn to scale unless specifically indicated.

Reference throughout this specification to “an embodiment” or “the embodiment” means that a particular feature, structure, or characteristic described in connection with that embodiment is included in at least one embodiment. Thus, the quoted phrases, or variations thereof, as recited throughout this specification are not necessarily all referring to the same embodiment.

FIGS.1-10illustrate different views of an embodiment of a reel device and related components.FIGS.11-13illustrate another embodiment of a reel device and related components. In certain views, the reel devices may be coupled to, or shown with, additional components not included in every view. Further, in some views, only selected components are illustrated, to provide detail into the relationship of the components. Some components may be shown in multiple views, but not discussed in connection with every view. Disclosure provided in connection with any figure is relevant and applicable to disclosure provided in connection with any other figure or embodiment.

FIGS.1-10depict an embodiment of a reel device100. As shown therein, the reel device100is generally comprised of a drive assembly110and a shift assembly210. As illustrated inFIGS.2and3, and the exploded view of the reel device100ofFIG.4, the drive assembly110may include one or more of an upper cap or upper member111, a drive axle120, a rotational engagement member130(e.g., such as a tri-spring), a release disk140, a lower cap or lower member150, a pin gear160, a cycloidal gear170, an outer gear180, and a spool250; and the shift assembly210may comprise one or more of a base211, a torque control member220(such as a spring), and a shift member230. The drive assembly110and/or the shift assembly210may be provided to a user in various configurations to accommodate a variety of uses. For example, the drive assembly110may be provided with any variety of selected drive mechanisms that facilitate different mechanical advantage ratios and/or the drive assembly110may be provided with a variety of different spool capacities to accommodate different cord lengths and/or sizes, etc. The drive assembly110and/or shift assembly210may be interchangeable with a differently configured drive assembly and/or shift assembly using any suitable tool-based or tool-less technique.

The upper cap111is generally domed shaped. The upper cap111can include a recess112disposed in an upper surface. The recess112can be shaped to receive a head121of the drive axle120. In the depicted embodiment, the recess112includes a central portion and three radial outwardly extending portions. In another embodiment, the recess112may include a single radial outwardly extending portion or another suitable configuration that mates with or is keyed to receive a head121of a drive axle120. The recess112can facilitate rotation of the drive axle120when the upper cap111is rotated. In some embodiments, the upper cap111may be optically clear or substantially transparent to facilitate visualization of the drive assembly110(e.g., to determine a status of the drive assembly110). In other embodiments, the upper cap111includes a transparent portion to facilitate visual observation of the drive assembly110(e.g., to determine the status of the drive assembly110).

The upper cap111includes a cavity113for selective disposition of one or more components of the drive assembly110. The cavity113can include a plurality of teeth114disposed around a circumference of the cavity113(shown inFIG.5B). The teeth114can be configured to engage with detents133of a rotational engagement member130. The teeth114may be of any suitable form. For example, the teeth114may include a plurality of rounded protrusions with a plurality of rounded recesses disposed between the protrusions. In another embodiment, the teeth114may be angled.

The upper cap111may also include a grip enhancing feature115. The grip enhancing feature115may be a plurality of nubs disposed around an outer circumference of the upper cap111, as shown inFIG.4. Alternatively, the grip enhancing feature115may be a plurality of finger depressions and ridges115adisposed around the perimeter of an upper cap111a, as depicted inFIG.9A, or a plurality of knurls115b,115cdisposed around the perimeter of upper caps111b,111c, as depicted inFIGS.9B and9C. Other configurations of the grip enhancing feature115are also contemplated and are within the scope of this disclosure. An over cap member (not depicted) can also be disposed over and/or coupled to the upper cap111as desired. For instance, a relatively large over cap can be disposed over and/or coupled to the upper cap111for increasing dexterity and/or leverage for patients with lower hand strength and/or grip. The over cap can be various sizes and/or shapes as desired. If desired, the over cap can also include a motor assembly included therein to control and/or adjust rotation of the upper cap111. Including a motor assembly in the over cap can be advantageous in converting a non-motorized device to a motorized device.

The drive axle120is shown inFIGS.4and5Ato include the head121, an upper shaft portion122, a centric shaft portion126, an eccentric shaft portion127, and a bore128. As discussed previously, the head121is configured to be moveably disposed within the recess112of the upper cap111. The depicted drive axle120includes a head121having a central portion and three radial outwardly extending arms. In other embodiments, the head121can include a single radial outwardly extending arm or another suitable configuration that mates with or is keyed to be disposed in the recess112of the upper cap111. The upper shaft portion122extends downwardly from the head121and includes an upper groove123and a lower groove124. The grooves123,124may be engaged by a retention clip135of the rotational engagement member130.

The centric shaft portion126extends downwardly from the upper shaft portion122. The centric shaft portion126may have a diameter larger than the upper shaft portion122and the eccentric shaft portion127. The centric shaft portion126can extend through and rotate within the pin gear160. The eccentric shaft portion127extends downwardly from the centric shaft portion126. A central vertical axis of the eccentric shaft portion127is radially offset from a longitudinal axis of the drive axle120. The eccentric shaft portion127can be configured to be rotationally coupled to the cycloidal gear170. A screw190may coaxially extend through the bore128of the drive axle120and the drive axle120may rotate around the screw190.

With continued reference toFIG.4, the rotational engagement member130includes a rotational engagement housing131and a retention clip135. The rotational engagement housing131is shown to include three spring arms132(e.g., a tri-spring). In other embodiments the rotational engagement housing131may include any suitable number of spring arms132. For example, the rotational engagement housing131can include one, two, four, five, or more spring arms132. Each of the spring arms132includes a detent133disposed at a free end of the spring arm132. The detents133may be configured to engage the teeth114of the upper cap111to rotate the rotational engagement member130as the upper cap111is rotated when the reel device100is in a pre-shifted configuration. The detents133may also be configured to releasably engage the teeth114of the upper cap111when the rotational engagement member130is prevented from rotating in a shifted configuration.

A retention clip135can be disposed within a groove134of the rotational engagement housing131. The retention clip135can be generally C-shaped with two parallel bars. The retention clip135can be configured to engage the upper groove123and the lower groove124of the drive axle120. For example, the retention clip135can be engaged with the lower groove124when the reel device100is in a pre or non-shifted and shifted configuration during uptake of the cord193(not shown). The retention clip135can be transitioned to engage with the upper groove123when the reel device100is in a released configuration to rapidly release tension on the cord193and allow the cord193to be unwound from the spool250. In some embodiments, the retention clip135can include flexible arms configured to engage the teeth114of the upper cap111.

The release disk140can be disposed adjacent the rotational engagement member130. As depicted, the release disk140includes a locking passage141disposed centrally through the release disk140. The locking passage141can be configured to couple with the pin gear160to rotate the pin gear160when the release disk140is rotated. As illustrated the locking passage141has a hexagonal shape. In other embodiments, the locking passage141may have any suitable shape that couples with the pin gear160, such as triangular, square, rectangular, pentagonal, etc. Retention clips142may extend upwardly from an upper surface of the release disk140. The retention clips142may fixedly couple the release disk140to the rotational engagement member130.

In some embodiments, the release disk140can be retained within the cavity113of the upper cap111by a release disk ring145coupled to the upper cap111such that when the upper cap111is displaced longitudinally upward, the release disk140is also displaced longitudinally upward. In some embodiments, the release disk ring145may be a snap release disk ring145aconfigured to snap into the upper cap111aas depicted inFIG.8A. In other embodiments, the retainer release disk ring145bis configured to couple to the upper cap111bas depicted inFIG.8B, or the release disk ring145cis configured to threadingly couple to the upper cap111cas depicted inFIG.8C. Other configurations of the release disk ring145are also contemplated and are within the scope of this disclosure.

The pin gear160is disposed adjacent the release disk140. As illustrated inFIG.4, the pin gear160includes an upper locking portion161and a lower portion162. The upper locking portion161is shaped to be lockingly received by the locking passage141of the release disk140. In other words, the shape of the upper locking portion161can be the same shape as the locking passage141. InFIG.5C, a plurality of pins163are shown to extend downwardly from the lower portion162. The pins163are disposed in a circular pattern adjacent a perimeter of the lower portion162. The number of pins163may be equivalent to the number of lobes171of the cycloidal gear170. A central passage164is disposed through the upper locking portion161and the lower portion162. The central passage164is sized to accommodate the centric shaft portion126of the drive axle120such that drive axle120can be rotated relative to the pin gear160.

As illustrated inFIG.4, the cycloidal or wobble gear170is disposed adjacent the pin gear160. The cycloidal gear170includes a plurality of radial outwardly extending lobes171and a plurality of radial inwardly extending recesses172disposed between the lobes171. The lobes171and recesses172are configured to operatively couple with inner lobes181and inner recesses182of the outer gear180. The number of the lobes171is dependent upon providing a drive ratio to achieve a desired mechanical advantage, as will be discussed below. A plurality of pin passages173are disposed through the cycloidal gear170adjacent the lobes171. The number of pin passages173may be equivalent to the number of lobes171. The pin passages173can be configured to receive the pins163of the pin gear160. The pins163may rotate around a perimeter of or circumnavigate the pin passages173as the cycloidal gear170is driven in a cycloid shaped path by the eccentric shaft portion127of the drive axle120. A passage174is disposed centrally through the cycloidal gear170. A diameter of the passage164may be sized to accommodate the eccentric shaft portion127and allow the eccentric shaft portion127to rotate relative to the cycloidal gear170.

The cycloidal gear170is disposed within a central passage185of the outer gear180. As shown, the outer gear180includes a plurality of inner lobes181and inner recesses182disposed between the inner lobes181. The inner lobes181are configured to be received by the recesses172of the cycloidal gear170and the inner recesses182are configured to receive the lobes171of the cycloidal gear170. The cycloidal gear170may drive rotation of the outer gear180in the same direction as the direction of rotation of the drive axle120. Thus, during use, the outer gear180is rotated in the same direction as the upper cap111, which also causes the spool250to rotate in the same direction. This differs from harmonic drive systems in which a wave generator causes a flex spline and associated spool to rotate in a direction opposite the wave generator.

The number of lobes171of the cycloidal gear170and the number of inner lobes181of the outer gear180can be varied and/or selected to achieve a drive ratio having a desired mechanical advantage. For example,FIG.6Adepicts a cycloidal gear170aand an outer gear180ahaving a drive ratio of 5:1. In other words, five rotations of the upper cap111produce one rotation of the outer gear180aand the spool250(not shown). In this depicted embodiment, the number of lobes171ais five and the number of inner recesses182ais six.FIG.6Bdepicts a configuration of a cycloidal gear170band an outer gear180bhaving a drive ratio of 7:1 meaning that seven rotations of the upper cap111result in one rotation of the outer gear180band the spool250. In this configuration, the number of lobes171bis seven and the number of inner recesses182bis eight.FIG.6Cdepicts a configuration of a cycloidal gear170cand an outer gear180chaving a drive ratio of 11:1 meaning that 11 rotations of the upper cap111result in one rotation of the outer gear180c. In this configuration, the number of lobes171cis 11 and the number of inner recesses182cis 12. Other configurations of the cycloidal gear170and the outer gear180are also contemplated and are within the scope of this disclosure. The mechanical advantage provided by the drive assembly110provides a benefit of reduced effort by a user to tighten a cord of an adjustable member.

The pin gear160, the cycloidal gear170, and the outer gear180may be disposed within a lower cap150. As illustrated inFIG.4, the lower cap150includes a top portion151and a bottom portion152. The top portion151includes retention clips153extending upwardly. The retention clips153slidingly couple the top portion151to channels or apertures143in the release disk140. The top portion151may also include lateral protrusions155to fixedly couple the top portion151to channels or apertures156in the bottom portion152. The top portion151may further include a central passage157through which the upper locking portion161of the pin gear160can rotatably extend.

The bottom portion152may include a plurality of recesses154and downwardly extending protrusions158configured to engage with the shift member230to prevent rotation of the lower cap150when the reel device100is in the shifted configuration.

The drive assembly110may further include a clip192(such as an e-clip) configured to couple with the screw190to retain the components of the drive assembly110within the cavity113of the upper cap111.

As previously mentioned, the drive assembly110and its components may be modular. For instance, a user may selectively choose a first drive assembly110that is designed to provide a desired mechanical advantage during use. Optionally, one or more components of the first drive assembly110may be removed from the shift assembly210and replaced with a different drive assembly110(or components) that is designed to provide a different mechanical advantage. For instance, different drive assemblies110can be configured with cycloidal gears170and outer gears180having different drive ratios. Thus, the entirety of the reel device100need not be replaced to change the mechanical advantage that is desired. This can be advantageous as the base211of the shift assembly210can remain mounted and/or coupled to another device as the drive assembly110(or components thereof) is quickly replaced and exchanged for another drive assembly110(or components). In further embodiments, such as the embodiment ofFIGS.11-13, the cycloidal gear470and outer gear480can be removed and/or replaced as desired to achieve a particular drive ratio. Further, as previously mentioned, the drive assembly110can be configured with a tool-less release for ease and convenience in switching between different drive assemblies110and/or related components.

With continued reference toFIG.4, the base211of the shift assembly210includes a sidewall213defining a cavity217. A plurality of base ramps212are disposed around a perimeter of the cavity217adjacent a bottom of the cavity217. A spool support member219is disposed at the bottom of the cavity217. An insert holder218extends upwardly from the bottom of the cavity217. The base211can also optionally comprise mounting members216for use in mounting the base211to another device (e.g., such as a prosthetic device). The mounting members216may be of any suitable configuration, such as feet (as shown inFIG.4), a collar, threads, protrusions, etc.

At least one cord passage214is disposed through the sidewall213. In some embodiments, the number of cord passages214may be two, three, four, or more. The cord passages214may be radially spaced at defined intervals, such as at about 180 degrees, 90 degrees, 45 degrees, etc. Other configurations are also contemplated. The base211may be configured to rotationally couple with the upper cap111.

A torque control member220is shown adjacent the bottom of the cavity217. The torque control member220may be a generally C-shaped spring member having a first end221and a second end222. The first end221may be couplable to the base211and the second end222may be couplable to the shift member230. The torque control member220may be configured to provide rotational resistance to the shift member230. The torque control member220can also be adjusted to change a tension force required to rotate the shift member230during shifting. Alternatively, in certain embodiments a motor or solenoid member may be coupled to the shift member230to rotate the shift member230during shifting.

The shift member230is rotationally disposed within the cavity217of the base211. As shown in the embodiment ofFIG.4, the shift member230may have a cylindrical shape. For instance, the shift member230can comprise a shift ring. In other embodiments, the shift member230may have another suitable shape. The shift member230includes an upper portion234and a lower portion235. The upper portion234includes upwardly extending protrusions236configured to engage with the recesses154of the lower cap150when the reel device100is in the shifted configuration. The lower portion235includes a plurality of downwardly extending ramps231configured to slidingly couple with the base ramps212. The lower portion235also includes downwardly extending protrusions232. The protrusions232may include a plurality of channels or apertures241configured to receive the second end222of the torque control member220. The apertures241can facilitate adjustment of the torque resistance when the reel device100is in use. For instance, the tension and torque required to rotate the shift member230and transition the reel device100to the shifted configuration can be selected and adjusted via changing the position of the torque control member220in the apertures241. In other embodiments, the torque control member220can be replaced with a stronger (e.g., thicker) torque control member220to adjust the tension and torque required to rotate the shift member230. In some embodiments, rotation of the shift member230in response to tension on the cord193may cause the cord193to be wound onto the spool250in a substantially repeatable and substantially uniform manner.

The shift member230further includes at least one cord passage238disposed through a wall of the shift member230. The shift member230may include any suitable number of cord passages238, such as two, three, four, or more. Further, the number of cord passages238may match the number of cord passages214disposed in the base211. A cord groove240may also be disposed around a perimeter of the shift member230. The cord groove240can be configured to align and allow the cord193to travel between the cord passage238of the shift member230and the cord passage214of the base211.

The spool250may be disposed adjacent the shift member230on the spool support member219and over the insert holder218such that the spool250may be rotatable around the insert holder218. The spool250includes an upper portion251, a lower portion252, and a cord receiving portion253. The cord receiving portion253may be various depths and/or widths depending on the desired cord capacity of the spool250. Further, spools250having different cord capacities may be interchanged without changing other elements of the reel device100. Spools250can also be switched and/or replaced as the base211remains mounted and/or coupled to another device. The upper portion251includes a plurality of upwardly extending protrusions254configured to engage the outer recesses184of the outer gear180to rotate the spool250in the same direction as the outer gear180and the upper cap111. In another embodiment, the outer gear180can be an integral component of the spool250rather than a separate component. The cord receiving portion253is disposed between the upper portion251and the lower portion252. The cord receiving portion253is configured to receive the cord193and wind the cord193around a core of the spool250. Cord start passages256extend from the cord receiving portion253through the upper portion251and the lower portion252. In another embodiment, the cord start passages256may extend through a core of the spool250. The cord start passages256are configured to facilitate securement of an end of the cord193to the spool250prior to uptake of the cord193by the spool250. In the illustrated embodiment, the spool250comprises a single cord start passage256. Additional cord start passages256can also be included. For instance, the spool250can include 2, 3, 4 or more cord start passages256disposed around the spool250. It will thus be appreciated that one or a plurality of cords can be utilized with the reel device100.

A threaded insert191may also be disposed within the insert holder218. The insert191may be configured to threadingly couple with the screw190that extends through the drive axle120to couple the drive assembly110and the shift assembly210together.

Without limitation, any suitable type and/or variety of cord193can be used with the reel device100disclosed herein. For instance, the cord193may be an elongate flexible member comprising any suitable material, including, but not limited to, polymeric materials, metallic materials, and combinations thereof. In some embodiments, the cord193comprises polymeric materials such as nylon. In other embodiments, the cord193comprises metallic materials, such as steel. Other types of cords193can also be used. The cord193can also comprise braided materials as desired. The diameter and shape of the cord193may also vary depending on the application. For example, the transverse cross-sectional shape may be circular, triangular, square, oval, etc. The cord193can also be referred to as a tensioning member. In yet further embodiments, a strap member having a greater width than thickness can be used.

FIGS.7A-7Cdepict the reel device100in various configurations of operation.FIG.7Adepicts a cross-sectional view of the reel device100in a pre or non-shifted configuration.FIG.7Bdepicts a cross-sectional view of the reel device100in a shifted configuration.FIG.7Cdepicts a cross-sectional view of the reel device100in a released configuration.

Referring toFIG.7A, in the pre or non-shifted configuration the upper cap111is positioned in a depressed state where the upper cap111is adjacent the base211. The head121of the drive axle120is positioned in an upper portion of the recess112of the upper cap111. The detents133of the rotational engagement member130are engaging the teeth114of the upper cap111. The retention clip135of the rotational engagement member130is disposed in the lower groove124of the drive axle120. The release disk140is coupled to the rotational engagement member130. The lower cap150is coupled to the release disk140with substantially no separation between the two. The upper locking portion161of the pin gear160is disposed within the locking passage141of the release disk140. The pins163of the pin gear160are disposed within the pin passages173of the cycloidal gear170. The pin gear160is disposed around the centric shaft portion126of the drive axle120. The outer recesses184of the outer gear180are engaging the upwardly extending protrusions254of the spool250. The shift member230is positioned adjacent the bottom of the cavity217of the base211such that the ramps231are adjacent a bottom of the base ramps212. The torque control member220is in a substantially non-torqued state. The ends of the cord193are coupled to the spool250. The cord193passes through the cord passages238(not shown) of the shift member230and the cord passages214of the base211. The cord passages238of the shift member230and the cord passages214of the base211are not aligned.

In the pre-shifted configuration, the upper cap111can be gripped and rotated by a user in a either a first or second direction. Alternatively, the upper cap111can be rotated by a motor coupled to the upper cap111. As the upper cap111is rotated, the detents133of the rotational engagement member130engage with the teeth114of the upper cap111to facilitate rotation of the drive axle120, the rotational engagement member130, the release disk140, the lower cap150, the pin gear160, the cycloidal gear170, the outer gear180, and the spool250at a 1:1 drive ratio (or an approximately 1:1 drive ratio), all in the same rotational direction. In other words, as the upper cap111is rotated once, the spool250is also rotated once, in the same rotational direction. This facilitates a rapid uptake of the cord193by the spool250to quickly reduce a slack length of the cord193.

The pathway of the cord193in the pre or non-shifted configuration is as follows: the cord193travels through the cord passage214of the base211, along the cord groove240around a portion of the shift member230, though the cord passage238of the shift member230, and around the spool250. As the tension force on the cord193increases, the cord193applies a torque force on the shift member230to rotate the shift member230to a shifted position where the cord passages214of the base211align with the cord passages238of the shift member230. This shifted position is referred to as the shifted configuration and is depicted inFIG.7B. In some embodiments, this pathway of the cord193can provide a substantially repeatable and substantially uniform winding pattern around the spool250. Without being bound to any particular theory, the tension force on the cord193as it travels from the cord passage214of the base211to the spool250can aid in providing this substantially repeatable and substantially uniform winding pattern. Further, in the depicted embodiment, two ends of the cord193are shown being wound around the spool250. In other embodiments, only one end of the cord193is configured to be wound around the spool250. For instance, the second end of the cord193may be coupled to the reel device100at a location such that it is fixed and does not wind around the spool250. In another instance, the second end of the cord193can be coupled to a separate device entirely (such as the adjustable device for which the reel device100is configured for use). More than one cord193can also be used (e.g., one or both ends of two or more separate cords can be coupled to and wound around the spool250.)

Referring toFIG.7B, in the shifted configuration the upper cap111is positioned in a depressed state where the upper cap111is adjacent the base211. The head121of the drive axle120is positioned in an upper portion of the recess112of the upper cap111. The detents133of the rotational engagement member130are releasably engaging the teeth114of the upper cap111. The retention clip135of the rotational engagement member130is disposed in the lower groove124of the drive axle120. The release disk140is coupled to the rotational engagement member130. The lower cap150is coupled to the release disk140with essentially no separation between the two. The upper locking portion161of the pin gear160is disposed within the locking passage141of the release disk140. The pins163of the pin gear160are disposed within the pin passages173of the cycloidal gear170. The pin gear160is disposed around the centric shaft portion126of the drive axle120. At least one of the lobes171of the cycloidal gear170is coupled with the inner recesses182of the outer gear180. The cycloidal gear170is disposed around the eccentric shaft portion127of the drive axle120. The outer recesses184of the outer gear180are engaging the upwardly extending protrusions254of the spool250. The upwardly extending protrusions236of the shift member230are engaging the recesses154of the lower cap150. The ramps231are disposed adjacent a top of the base ramps212such that the shift member230is shifted upwards. The cord193is partially wrapped around the spool250and passes through the cord passages238of the shift member230and the cord passages214of the base211. The cord passages238and the cord passages214are aligned.

As previously discussed, the reel device100can be automatically transitioned from the pre or non-shifted configuration to the shifted configuration when the upper cap111is gripped and rotated by a user in a single direction. For example, as the upper cap111is rotated, tension is increased on the cord193causing an increased torque force on the shift member230. This increased torque force causes the shift member230to be partially rotated. During the partial rotation of the shift member230, the ramps231slidingly engage with the base ramps212, causing the shift member230to move upward and the cord passages238of the base211and the cord passages214of the shift member230to align. When the shift member230is moved upwards, the upwardly extending protrusions236engage with the recesses154of the lower cap150. When the shift member230engages with the lower cap150, rotation of the lower cap150, the release disk140, and the rotational engagement member130is prevented.

As the upper cap111continues to be rotated, the detents133of the rotational engagement member130releasably engage with the teeth114as the rotational engagement member130is prevented from rotating with the upper cap111. As the detents133releasably engage with the teeth114, an audible and/or tactile feedback indicator is provided to the user to indicate the reel device100has automatically shifted to the shifted configuration. The audible and/or tactile feedback indicator may additionally allow the user to dial in a known and/or substantially repeatable cord tension. The audible and/or tactile feedback indicator may indicate 90, 180, 270, and 360 degrees rotation of the upper cap111. Other audible and/or tactile feedback indicators are also within the scope of this disclosure. The drive axle120continues to be rotated by the upper cap111. The pin gear160remains rotationally stationary as the eccentric shaft portion127drives the cycloidal gear170in a cycloidal shaped path. The pin passages173of the cycloidal gear170are circumscribed by the stationary pins163to define the cycloid shaped path. As the cycloidal gear170is driven in the cycloid shaped path, the lobes171of the cycloidal gear170engage with the inner lobes181and inner recesses182of the outer gear180to drive rotation of the outer gear180and the spool250in the same direction as the rotation of the upper cap111and drive axle120.

In the shifted configuration, the 1:1 drive ratio (or approximately 1:1 drive ratio) of the upper cap111and the spool250is stopped as the reel device100transitions to a different drive ratio that may provide mechanical advantage. The engagement of the cycloidal gear170with the outer gear180produces a drive ratio that provides a mechanical advantage to the reel device100. A range of drive ratios may be from about 2:1 to about 15:1 (or higher, such as from about 4:1 to about 15:1, 20:1, 25:1, 30:1, 40:1, 60:1, 70:1, 80:1, 90:1, 100:1, 110:1, 120:1, 130:1, 140:1, or 150:1). This results in increased tension on the cord193with less rotational force on the upper cap111. For example, in the shifted configuration, when the drive ratio is 4:1, the user can rotate the upper cap111four rotations to achieve one rotation of the spool250.

In some embodiments, the user may reverse rotation of the upper cap111to unwind the cord193or lessen the tension. In certain embodiments, engagement of the cycloidal gear170with the outer gear180prevents rotation of the spool250in the reverse direction absent the user rotating the upper cap111. Thus, the tension on the cord193may remain absent reverse rotation of the upper cap111. In other embodiments, the reel device100may be prevented from reverse rotation without transitioning the reel device100to a released configuration. In yet other embodiments, the reel device100may comprise a selective backcheck feature configured to prevent inadvertent rotation of the upper cap111in the reverse direction (e.g., the direction opposite of the winding direction). In yet another embodiment, the reel device100may include an adjustable clutch mechanism to prevent over-tensioning of the cord193and to permit the user to tighten the cord193to a repeatable tightness. The clutch mechanism may allow the drive assembly110to slip when a threshold tension force on the cord193is exceeded. The clutch mechanism can also be tunable to a desired threshold tension force. Further, when the cord tension and torque forces reduce to below the threshold tension and torque forces, the reel device can automatically de-shift or transition back to the pre-shifted configuration. It will further be appreciated that the reel device100can work in either direction. For instance, if you begin tightening the reel device100by rotating the upper cap111in the clockwise direction, a counterclockwise rotation of the upper cap111can unwind or loosen the cord193. Similarly, if you begin tightening the reel device100by rotating the upper cap111in the counterclockwise direction, a clockwise rotation of the upper cap111can unwind or loosen the cord193.

In some embodiments, the reel device100can further include a release configuration for quick or rapid release of the cord193. Such a release configuration, shown inFIG.7C, can be obtained by pulling the upper cap111upwards. Referring toFIG.7C, in the release configuration, the upper cap111is positioned in a raised state where the upper cap111is spaced apart from the base211. The head121of the drive axle120is positioned in a lower portion of the recess112of the upper cap111. The detents133of the rotational engagement member130are engaging the teeth114of the upper cap111. The retention clip135of the rotational engagement member130is disposed in the upper groove123of the drive axle120to retain the upper cap111in the raised position. The release disk140is coupled to the rotational engagement member130. The lower cap150is coupled to the release disk140with separation between the two. The upper locking portion161of the pin gear160is displaced from the locking passage141of the release disk140, allowing the spool250to freely rotate and the tension force on the cord193to be released.

With continued reference toFIG.7C, the pins163of the pin gear160remain disposed within the pin passages173of the cycloidal gear170, with the pin gear160disposed around the centric shaft portion126of the drive axle120. The outer recesses184of the outer gear180are engaging the upwardly extending protrusions254of the spool250. The shift member230has moved back down the base ramps212such that it is positioned adjacent the bottom of the cavity217of the base211. The torque control member220has transitioned to a substantially non-torqued state as the tension on the cord193has been released. Absent tension on the cord193, the cord passages238of the shift member230and the cord passages214of the base211have also transitioned back to a non-aligned orientation.

The reel device100can be transitioned from the pre or non-shifted and shifted configurations to the released configuration when the upper cap111is gripped and displaced upward. As the upper cap111is displaced, the rotational engagement member130and the release disk140are also displaced upwardly relative to the lower cap150. When the release disk140is displaced upwardly, the pin gear160disengages from the release disk140to allow free rotation of the pin gear160, the cycloidal gear170, the outer gear180, and the spool250. This free rotation allows the cord193to be rapidly unwound from the spool250by applying an outwardly directed force to the cord193.

In the released configuration, the reel device100may also provide a visual feedback indicator that indicates the reel device100is in the released configuration. In the illustrated embodiment ofFIG.7C, the visual feedback indicator is exposure of a wall of the upper portion of the recess112of the upper cap111. In some embodiments, the wall may include a color that is easily visible, such as red, blue, green, etc. In another embodiment, the visual feedback indicator may be exposure of a portion of the shift member230between the upper cap111and the base211. Other visual feedback indicators are also within the scope of this disclosure. The reel device100may also provide a tactile feedback to indicate that the reel device100has been transitioned to the released configuration. In the illustrated embodiment ofFIG.7C, the tactile indicator can be caused by movement of the retention clip135of the rotational engagement member130from the lower groove124to the upper groove123of the drive axle120. Other tactile feedback indicators are also within the scope of this disclosure.

In some embodiments, the disclosed reel device100can be configured as a low-profile device with a minimal height or thickness having good rotational mechanical advantage. For instance, without limitation, it will be appreciated that the reel device100(and the reel device400ofFIGS.11-13) may have an overall height ranging from about mm to about 25.0 mm, or from about 17.0 mm to about 23.0 mm in the pre or non-shifted, shifted, and released configurations. Such a height may be accomplished through a relatively small thickness of the cycloidal gear170. For example, the thickness of the cycloidal gear170can range from about 0.5 mm to about 3.0 mm, or from about 1.0 mm to about 3.0 mm. Thus, the range of a ratio of the overall height in the pre or non-shifted and shifted configurations to the thickness of the cycloidal gear170can be from about 5:1 to about 20:1. In other embodiments, the reel device100may be scalable to any suitable physical size dependent upon its application. For instance, the reel device100may have an overall height ranging from as small as about 10.0 mm to 12.0 mm to as large as 50.0 mm or larger in the pre or non-shifted, shifted, and released configurations The reel device100can also be classified by its gear ratio in relation to its relatively small size. For instance, in some embodiments, the gear ratio of the reel device100can be between about 4:1 and about 100:1, the thickness of the cycloidal gear170can be between about 1.0 mm to about 3.0 mm, and/or the thickness of the reel device100may be between about 15.0 mm to about 25.0 mm.

As can be appreciated, the reel device100may also be used to adjust a cord on various types of articles and devices. For example, the reel device100may be used to adjust one or more of a medical device, a prosthetic device, an orthotic device, a shoe, a boot, a ski boot, a snowboard boot, clothing apparel (such as a coat), a helmet, etc. Use of the reel device100on other types of devices are also contemplated, including, but not limited to different types of equipment (including, but not limited to, industrial equipment, outdoor equipment, and sporting equipment), protective products, securing straps, robotics, packs, luggage, action sports products, etc.

As an example, in a certain embodiment, the reel device100may be a component of an adjustable prosthetic system300that comprises a prosthesis310, the reel device100, the cord193, an adjustable member320, and a socket330, as shown inFIG.10. The prosthesis310may be configured for use with residual portions (i.e., residuum) of an amputated leg, such as a leg that has undergone a transfemoral (i.e., above-knee) or transtibial (i.e., below-knee) amputation and an amputated arm (e.g., after an above-elbow or below-elbow amputation).

With continued reference toFIG.10, the reel device100may be coupled to the prosthesis310using any suitable technique. For example, the reel device100may be coupled using fasteners, bonding, welding, etc. The adjustable member320may partially surround the socket330. The cord193may be threaded through a plurality of guide members321that are coupled to the adjustable member320. In some embodiments, the adjustable prosthetic system may include a motor operably coupled to the reel device100and configured to operate the reel device100to adjust the adjustable member320.

In use, the residuum may be inserted into the socket330of the adjustable prosthetic system300. The cord193may be threaded through the guide members321of the adjustable member320and coupled to the reel device100. The reel device100may be actuated as previously described to tighten the cord193such that a shape of the adjustable member320is adjusted to provide a better fit of the socket330to the residuum. Other uses are also contemplated.

FIGS.11-13depict another embodiment of a reel device that resembles the reel device100described above in certain respects. Accordingly, like features are designated with like reference numerals, with the leading digit incremented to “4.” For example, the embodiment depicted inFIGS.11-13includes a drive assembly410that may, in some respects, resemble the drive assembly110ofFIG.1. Relevant disclosure set forth above regarding similarly identified features thus may not be repeated hereafter. Moreover, specific features of the reel device100and related components shown inFIGS.1-10may not be shown or identified by a reference numeral in the drawings or specifically discussed in the written description that follows. However, such features may clearly be the same, or substantially the same, as features depicted in other embodiments and/or described with respect to such embodiments. Accordingly, the relevant descriptions of such features apply equally to the features of the reel device400and related components depicted inFIGS.11-13. Any suitable combination of the features, and variations of the same, described with respect to the reel device100and related components illustrated inFIGS.1-10can be employed with the reel device400and related components ofFIGS.11-13, and vice versa. This pattern of disclosure applies equally to further embodiments depicted in subsequent figures and described hereafter, wherein the leading digits may be further incremented.

FIGS.11-13depict another embodiment of a reel device400. As shown inFIG.11, the reel device400is generally comprised of a drive assembly410, a shift assembly510, and a collar515. As illustrated in the exploded view of the reel device400ofFIG.12, the drive assembly410may include one or more of an upper cap or upper member411, a drive axle420, a lower cap or lower member450, a pin gear460, a cycloidal gear470, an outer gear480, and/or a spool550; and the shift assembly510may comprise one or more of a base511, a torque control member520(such as a spring), and/or a shift member530. The drive assembly410and/or the shift assembly510may be provided to a user in various configurations to accommodate a variety of uses. For example, the drive assembly410may be provided with any variety of selected drive mechanisms that facilitate different mechanical advantage ratios and/or the drive assembly410may be provided with a variety of different spool capacities to accommodate different cord lengths, etc. The drive assembly410and/or shift assembly510(or components thereof) may also be interchangeable with a differently configured drive assembly and/or shift assembly (or related components) using any suitable tool-based or tool-less technique. For instance, a first cycloidal gear470and a first outer gear480can be substituted with a second cycloidal gear470and a second outer gear480to achieve a different drive ratio.

The upper cap411is generally circular shaped. The upper cap411can include a recess412disposed in an upper surface. The recess412can be sized and shaped to receive a head421of the drive axle420. A drive axle passage417can extend through the upper cap411. The upper cap411may include a clutch446including a threaded passage416in communication with the drive axle passage417. The threaded passage416can receive a pin418, a resilient member419, and an adjustable member425(e.g., threaded set screw).

As illustrated inFIGS.12and13, the upper cap411includes a cavity413for selective disposition of the lower cap450. The cavity413can include one or more sockets437configured to receive and retain one or more latch member439(e.g., spring ball member). The lower cap450is generally disk shaped and includes a plurality of recesses or dimples444(shown inFIG.12) configured to receive the ball of the latch member439. The dimples444can be disposed on a top portion451in a circular pattern adjacent a perimeter of the top portion451. The lower cap450also includes one or more recesses454disposed in a circular pattern adjacent a perimeter of a bottom portion452. The recesses454can receive upwardly extending protrusions536of the shift member530to engage the lower cap450with the shift member530. Further, the lower cap450includes one or more pins459extending away from the bottom portion452. The pins459may be disposed in a circular pattern. The pins459can be received within pin passages465of the pin gear460. A central passage466is disposed through the lower cap450. The central passage466is sized to accommodate a centric shaft portion426of the drive axle420such that drive axle420can be rotated relative to the lower cap450. The cavity413further includes an internal threaded passage416configured to receive a retention ring445. The retention ring445can retain the lower cap450within the cavity413.

The drive axle420is shown inFIG.12to include the head421, the centric shaft portion426, and an eccentric shaft portion427. As discussed previously, the head421is configured to be disposed within the recess412of the upper cap411. The centric shaft portion426extends downwardly from the head421. The centric shaft portion426may have a diameter smaller than the head421and larger than the eccentric shaft portion427. The centric shaft portion426can extend through and rotate within the lower cap450and the pin gear460. A pin recess419is disposed in the centric shaft portion426and is configured to be operatively coupled with the pin418for operation of the clutch446.

The eccentric shaft portion427extends downwardly from the centric shaft portion426. A central vertical axis of the eccentric shaft portion427is radially offset from a longitudinal axis of the drive axle420. The eccentric shaft portion427can be configured to be rotationally coupled to the cycloidal gear470. A threaded bolt494can be coupled to the drive axle420adjacent the eccentric shaft portion427to retain the drive assembly410proximate to the shift assembly510. As desired, the drive axle420can be threaded/unthreaded from the bolt494to couple and/or uncouple the drive assembly410and the shift assembly510.

The pin gear460is disposed between the lower cap450and the cycloidal gear470. As illustrated, the pin gear460includes an upper portion461and a lower portion462. The upper portion461includes a plurality of pin passages465configured to receive the pins459of the lower cap450. The number of pin passages465may be equivalent to the number of pins459. A plurality of gear pins463extend downwardly from the lower portion462. The gear pins463are disposed in a circular pattern adjacent a perimeter of the lower portion462. The number of gear pins463may be equivalent to the number of pin passages473of the cycloidal gear470. A central passage464is disposed through the pin gear460. The central passage464is sized to accommodate the centric shaft portion426of the drive axle420such that the drive axle420can be rotated relative to the pin gear460.

The cycloidal or wobble gear470is disposed adjacent the pin gear460. The cycloidal gear470includes a plurality of radial outwardly extending lobes471and a plurality of radial inwardly extending recesses472disposed between the lobes471. The lobes471and recesses472are configured to operatively couple with inner lobes481and inner recesses482of the outer gear480. A plurality of pin passages473are disposed through the cycloidal gear470adjacent the lobes471. The pin passages473can be configured to receive the gear pins463of the pin gear460. The gear pins463may rotate around a perimeter of or circumnavigate the pin passages473as the cycloidal gear470is driven in a cycloid shaped path by the eccentric shaft portion427of the drive axle420as the drive axle420is rotated. A passage474is disposed centrally through the cycloidal gear470. A diameter of the passage464may be sized to accommodate the eccentric shaft portion427and allow the eccentric shaft portion427to rotate relative to the cycloidal gear470.

The cycloidal gear470is disposed within the outer gear480. As shown, the outer gear480includes a plurality of inner lobes481and inner recesses482disposed between the inner lobes481. The inner lobes481are configured to be received by the recesses472of the cycloidal gear470and the inner recesses482are configured to receive the lobes471of the cycloidal gear470. As discussed with the embodiment ofFIGS.1-4, the cycloidal gear470may drive rotation of the outer gear480in the same direction as the direction of rotation of the drive axle420and/or upper cap411.

As previously mentioned, a portion of the drive assembly410may be modular. For instance, a user may selectively choose a first drive assembly410that is designed to provide a desired mechanical advantage during use. Optionally, components of the first drive assembly410may be replaced with different components that are designed to provide a different mechanical advantage. For instance, different cycloidal gears470and outer gears480having different drive ratios may be used. Thus, the entirety of the reel device400need not be replaced to change the mechanical advantage that is desired. This can be advantageous as the collar515of the shift assembly510can remain mounted and/or coupled to another device as the components of the drive assembly410are quickly replaced and exchanged for other components.

With continued reference toFIG.12, the base511of the shift assembly510includes a sidewall513defining a cavity517. One or a plurality of slots512are disposed in the sidewall513. The slots512include a lower portion and an upper portion. A spool support member519is disposed centrally within the cavity517. The threaded bolt494extends through the spool support member519. The base511can be removably disposed within the collar515. A clip516can releasably retain the base511within the collar515. The collar515may be mounted to another device (e.g., such as a prosthetic device or orthotic device).

At least one cord passage514is disposed through the sidewall513. In some embodiments, the number of cord passages514may be two, three, four, or more. The cord passages514may be radially spaced at defined intervals, such as at about 180 degrees, 90 degrees, 45 degrees, etc. Other configurations are also contemplated.

A torque control member520is disposed within the cavity517. In some embodiments, the torque control member520is disposed within a sleeve, slot, or channel within the cavity517. The torque control member520may be a resilient member (e.g., such as a compression spring) having a first end and a second end. The first end may be couplable to or otherwise interface with the base511and the second end may be couplable to or otherwise interface with the shift member530. The torque control member520may be configured to provide rotational resistance to the shift member530to prevent the shift member530from rotating until a threshold rotational force is exceeded. Further, the torque control member520can apply a rotational force to the shift member530causing and/or biasing the shift member530to rotate from a shifted configuration to a pre or non-shifted configuration. The torque control member520can also be tunable and/or modified to adjust the threshold rotation force that is required to rotate the shift member530. For instance, a torque control member520comprising a resilient member (e.g., a compression spring) can be substituted with another resilient member or otherwise modified to change the properties of the torque control member520as desired.

The shift member530is rotationally disposed within the cavity517of the base511. As shown in the embodiment ofFIG.12, the shift member530may have a cylindrical shape. For instance, the shift member530can comprise a shift ring. In other embodiments, the shift member530may have another suitable shape. The shift member530includes upwardly extending protrusions536configured to engage with the recesses454of the lower cap450when the reel device400is in the shifted state.

The shift member530further includes at least one cord passage538disposed through a wall of the shift member530. The shift member530may include any suitable number of cord passages538, such as two, three, four, or more. Further, the number of cord passages538may match the number of cord passages514disposed in the base511. A cord groove540may also be disposed around a perimeter of the shift member530. The cord groove540can be configured to align and allow the cord493(not shown) to travel between the cord passage538of the shift member530and the cord passage514of the base511.

The shift member530includes at least one slot pin529extending radially outward from the side wall. The slot pin529is configured to be slidably disposed within the slot512of the base511. In some embodiments, the slot pin529may be an integral part of the shift member530. In other embodiments, the slot pin529may be a bolt (e.g., hex bolt) threadingly coupled to the shift member530. If desired, a plurality of slot pins529can be used, such as 2, 3, 4 or more. For instance, in some embodiments, a plurality of slot pins529are slidably disposed within a plurality of slots512that are disposed around the circumference of the base511.

The spool550may be disposed adjacent the shift member530on the spool support member519such that the spool550may be rotatable around spool support member519. The spool550can be coupled with the outer gear480to rotate the spool550in the same direction as outer gear480and the upper cap411. In some embodiments, the spool550is integral with the outer gear480. In other embodiments, the spool550and outer gear480are separate components coupled together.

During use, the upper cap411of the reel device400is positioned adjacent the base511. The head421of the drive axle420is positioned in the recess412of the upper cap411. An end of the pin418of the clutch446is disposed in the pin recess419of the drive axle420. The pin418is pressed into the pin recess419by an adjustable force applied by the adjustable member425to allow the upper cap411to rotate the drive axle420until a desired threshold rotational force is exceeded. When the desired threshold rotational force is exceeded, the pin418is displaced from the pin recess419allowing the upper cap411to be rotated without rotation of the drive axle420. The force applied to the pin418can be adjusted by rotation of the adjustable member425by a tool. For example, the adjustable member425can be rotated clockwise to increase the force applied to the pin418resulting in an increase in the rotational release force. Adjusting the force applied to the pin418can modify the desired threshold force that is required to activate the clutch446and allow the upper cap411to rotate without rotation of the drive axle420.

When the reel device400is in the pre or non-shifted configuration, the lower cap450is disposed within the cavity413of the upper cap411. The balls of the latch members439are disposed within the dimples444of the lower cap450such that the lower cap450is rotationally engaged with the upper cap411. The pins459of the lower cap450are disposed within the pin passages465of the pin gear460. The gear pins463of the pin gear460are disposed within the pin passages473of the cycloidal gear470. The pin gear460is disposed around the centric shaft portion426of the drive axle420. The shift member530is positioned adjacent the bottom of the cavity519of the base511such that the slot pins529are disposed in the vertical portion of the slot512. The torque control member520is in a substantially non-compressed state. At a user's discretion, an end of the cord493can be coupled to the spool550(e.g., such as via one or more cord start passages556). The cord493can pass through a cord passage538of the shift member530and a cord passage514of the base511. The cord passages538of the shift member530and the cord passages514of the base511are not aligned.

In the pre or non-shifted configuration, the upper cap411can be gripped and rotated by a user in a first direction (e.g., either clockwise or counterclockwise) to apply tension to the cord493. As the upper cap411is rotated, the pin418engages with the pin recess419and the latch members439engage with the dimples444of the lower cap450to facilitate rotation of the drive axle420, the lower cap450, the pin gear460, the cycloidal gear470, the outer gear480, and the spool550at a 1:1 drive ratio (or an approximately 1:1 drive ratio), all in the same rotational direction. In other words, as the upper cap411is rotated approximately once, the spool550is also rotated approximately once, in the same rotational direction. This facilitates a rapid uptake of the cord493by the spool550to quickly reduce a slack length of the cord493.

The reel device400can be automatically transitioned from the pre or non-shifted configuration to the shifted configuration as the tension of the cord493is increased via rotation of the upper cap411. For example, as the upper cap411is rotated, tension is increased on the cord493causing an increased torque force on the shift member530. This increased torque force causes the shift member530to be rotated as the cord moves the cord passage538of the shift member530and the cord passage514of the base511into alignment. As the shift member530rotates, the torque control member520is also compressed, resulting in a force in the opposite direction that opposes rotation of the shift member530. When the tension and torque force from the cord493exceeds a threshold level (e.g., the level of force applied from the torque control member520), the shift member530will rotate to the shifted configuration. During the rotation of the shift member530, slot pins529are displaced from the lower portion of the slot512to the upper portion of the slot512causing the shift member530to move upward as the cord passages538of the base511and the cord passages514of the shift member530align. The rotation of the shift member530may be further restrained until a threshold tension is exceeded due to a shoulder transition of the lower portion to the upper portion of the slot512. In other words, the slot pins529are restrained from transitioning from the lower portion to the upper portion of the slots512until a threshold tension on the cord493is exceeded because the slot pins529are required to pass over the transition shoulder resulting in a sudden shift of the shift member530. When the shift member530is moved upwards, the upwardly extending protrusions536engage with the recesses454of the lower cap450. When the shift member530engages with the lower cap450, rotation of the lower cap450is prevented.

As the upper cap411continues to be rotated, the latch members439releasably engage with the dimples444as the lower cap450is prevented from rotating with the upper cap411. As the latch members439releasably engage with the dimples444, an audible and/or tactile feedback indicator (e.g., a click) is provided to the user to indicate the reel device400has automatically shifted to the shifted configuration. The audible and/or tactile feedback indicator may additionally allow the user to dial in a known and/or substantially repeatable cord tension. The drive axle420continues to be rotated by the upper cap411. The pin gear460remains rotationally stationary as the eccentric shaft portion427drives the cycloidal gear470in a cycloidal shaped path. The pin passages473of the cycloidal gear470are circumscribed by the stationary gear pins463to define the cycloid shaped path. As the cycloidal gear470is driven in the cycloid shaped path, the lobes471of the cycloidal gear470engage with the inner lobes481and inner recesses482of the outer gear480to drive rotation of the outer gear480and the spool550in the same direction as the rotation of the upper cap411and drive axle420.

In the shifted configuration, the 1:1 drive ratio (or approximately 1:1 drive ratio) of the upper cap411and the spool550is stopped as the reel device400transitions to a different drive ratio that may provide mechanical advantage. The engagement of the cycloidal gear470with the outer gear480produces a drive ratio that provides a mechanical advantage to the reel device400. A range of drive ratios may be from about 2:1 to about 15:1 (or higher, such as from about 4:1 to about 15:1, 20:1, 25:1, 30:1, 40:1, 60:1, 70:1, 80:1, 90:1, 100:1, 110:1, 120:1, 130:1, 140:1, or 150:1) and may be about 7:1. This results in increased tension on the cord493with less rotational force on the upper cap411. For example, in the shifted configuration, when the drive ratio is 7:1, the user can rotate the upper cap411seven rotations to achieve one rotation of the spool550.

As the upper cap411continues to be rotated, tension on the cord493increases causing a torque increase. When the torque exceeds a desired threshold, the clutch446is actuated wherein the pin418is displaced from the pin recess419when the resilient member419is compressed between the pin418and the adjustable member425. The upper cap411can be rotated one revolution without rotation of the drive axle420and the spool550. Following one revolution, the pin418is again disposed in the pin recess419. Upon return of the pin418to the pin recess419an audible and tactile feedback (e.g., a click) is transmitted to the user to indicate that a desired or maximum tension has been applied to the cord493.

In some embodiments, the user may reverse rotation of the upper cap411to unwind the cord493or lessen the tension. In certain embodiments, the upper cap411can be rotated from about two rotations to about five rotations to release tension on and unwind the cord493from the spool550. As tension in the cord493is reduced, the reel device400automatically transitions from the shifted configured back to the pre or non-shifted configuration. For example, in the shifted configuration, the torque control member520is in a compressed state thereby exerting a force on the shift member530that is towards the pre or non-shifted configuration. As tension in the cord493is reduced, the force applied by the torque control member520exceeds the torque force applied by the cord493causing the shift member530to transition from the shifted configuration and back to the pre or non-shifted configuration. During this transition, the slot pins529slide within the slots512from the upper position and back to the lower position causing the shift member530to be moved downwards. The downward movement of the shift member530causes the upwardly extending protrusions536to disengage with the recesses454of the lower cap450thereby allowing the lower cap to freely rotate with the upper cap411. In such a manner, the reel device400can be shifted and unshifted automatically as the user operates the device400.

It will further be appreciated that the reel device400can work in either direction. For instance, if you begin tightening the reel device400by rotating the upper cap411in the clockwise direction, a counterclockwise rotation of the upper cap411can unwind or loosen the cord493. Similarly, if you begin tightening the reel device400by rotating the upper cap411in the counterclockwise direction, a clockwise rotation of the upper cap411can unwind or loosen the cord493.

It will also be appreciated that any number of cords493can be used with the device400. Thus, any reference to the use of a single cord493is merely exemplary and not limiting in any way. Rather, a plurality of cords493(e.g., 2, 3, 4 or more) can also be used with the device400as desired.

It will be appreciated that any methods disclosed herein comprise one or more steps or actions for performing the described method. The method steps and/or actions may be interchanged with one another. In other words, unless a specific order of steps or actions is required for proper operation of the embodiment, the order and/or use of specific steps and/or actions may be modified. For example, a method of adjusting an adjustable member may include one or more of the following steps: obtaining a reel device, comprising: a drive assembly and an automatic shift assembly; threading an elongate cord into the reel device; rotating the drive assembly at a first drive ratio of approximately 1:1; applying tension on the elongate cord to apply a torque force to the reel device that exceeds a threshold actuation torque force; and automatically actuating the shift assembly to transition the drive assembly to a second drive ratio of from about 2:1 to about 150:1. Other steps are also contemplated.

Similarly, in the above description of embodiments, various features are sometimes grouped together in a single embodiment, figure, or description thereof for the purpose of streamlining the disclosure. This method of disclosure, however, is not to be interpreted as reflecting an intention that any claim requires more features than those expressly recited in that claim. Rather, as the following claims reflect, inventive aspects lie in a combination of fewer than all features of any single foregoing disclosed embodiment.

The phrases “coupled to” and “in communication with” refer to any form of interaction between two or more entities, including mechanical, electrical, magnetic, electromagnetic, fluid, and thermal interaction. Two components may be coupled to or in communication with each other even though they are not in direct contact with each other. For example, two components may be coupled to or in communication with each other through an intermediate component.

References to approximations are made throughout this specification, such as by use of the term “substantially.” For each such reference, it is to be understood that, in some embodiments, the value, feature, or characteristic may be specified without approximation. For example, where qualifiers such as “about” and “substantially” are used, these terms include within their scope the qualified words in the absence of their qualifiers. For example, where the term “substantially perpendicular” is recited with respect to a feature, it is understood that in further embodiments, the feature can have a precisely perpendicular configuration.

The terms “a” and “an” can be described as one, but not limited to one. For example, although the disclosure may recite a housing having “a stopper,” the disclosure also contemplates that the housing can have two or more stoppers.

Unless otherwise stated, all ranges include both endpoints and all numbers between the endpoints.

Recitation in the claims of the term “first” with respect to a feature or element does not necessarily imply the existence of a second or additional such feature or element. It will be apparent to those having skill in the art that changes may be made to the details of the above-described embodiments without departing from the underlying principles of the invention.

Without further elaboration, it is believed that one skilled in the art can use the preceding description to utilize the invention to its fullest extent. The claims and embodiments disclosed herein are to be construed as merely illustrative and exemplary, and not a limitation of the scope of the present disclosure in any way. It will be apparent to those having ordinary skill in the art, with the aid of the present disclosure, that changes may be made to the details of the above-described embodiments without departing from the underlying principles of the disclosure herein. In other words, various modifications and improvements of the embodiments specifically disclosed in the description above are within the scope of the appended claims. Moreover, the order of the steps or actions of the methods disclosed herein may be changed by those skilled in the art without departing from the scope of the present disclosure. In other words, unless a specific order of steps or actions is required for proper operation of the embodiment, the order or use of specific steps or actions may be modified. The scope of the invention is therefore defined by the following claims and their equivalents.