Patent ID: 12185796

DETAILED DESCRIPTION

The present disclosure describes a number of embodiments of adjustment devices that employ a spool that interfaces to and supports at least one tension line. Thus, while some embodiments of the adjustment devices have been shown without connection to a tension line, all of the adjustment devices can be used with one or more tension lines. Note that each one the adjustment devices can be part of a fit system or a line tensioning system as described herein.

As used herein, a “tension line” refers to a flexible elongate member that can be gathered and wound onto a spool and unwound therefrom. The material of the tension line can be inelastic in nature or possibly have some elasticity. The tension line can be a cord, rope, cable, filament, or lace having a generally round profile, as well as flat straps having rectangular or square profiles. The material of the tension line can be any material typically used as a tension line in the same application. Thus, for a footwear application, the tension line used by the adjustment device in accordance with this description may be made from the same material currently in use for shoelaces. Also, the materials used may differ from those typically used for the application. The materials used for the tension line can include metal (e.g., steel) cable, and polyester webbing.

As used herein, a “fit system” refers to an adjustment device connected to a wearable article with at least one tension line (flexible elongate members such as straps, cables, wires, etc.) with one or more attachment points or interfaces to the article or device.

As used herein, a “line tensioning system” refers to an adjustment device connected to a non-wearable article or structure with at least one tension line (flexible elongate members such as straps, cables, wires, etc.) with one or more attachment points or interfaces to the article, device, or structure. Similar to fit systems, the attachment points or interfaces may decrease in distance relative to one another or relative to the line tensioning system, which can be referred to as contraction or shortening. The adjustment devices used in line tensioning systems may operate in space without being directly mounted to an article or structure.

FIGS.1to13show details of a first embodiment of an adjustment device100in accordance with an aspect of the disclosure. The device100is intended to be used with at least one a tension line that can be wound and collected by the device100and unwound and dispensed therefrom.FIGS.1to3show the device100assembled from its component parts shown in exploded views inFIGS.4and5.

The device100includes a housing10that includes a base12and a removable cover14. The housing10surrounds a spool16, shown in greater detail inFIGS.4and5. The base12defines a plurality of holes12athrough which the flexible elongate member20(FIGS.8and9) can extend to connect to an axle16aof the spool16on which the spool rotates about a first axis.

The base12has a mounting flange12bthat define notches12cthat can provide an anti-rotation feature for the device10. For example, the mounting flange12bmay be received into a molded or otherwise formed material702of a wearable article, such as a prosthetic socket700(shown inFIGS.10-11and40-42) such that the formed material secures the mounting flange12band protrudes into the notches12cto prevent rotation of the flange12brelative to the article.

The cover14defines a central opening14a. The opening14ais coaxial with a central longitudinal axis A-A of the device100. The central opening is shown as being a hexagonal opening, the shape of the opening defined in cross-section to the longitudinal axis. As shown inFIGS.4and5, the base12has threads12dthat mate with threads14bof the cover14to form a removable threaded connection between the cover14and the base12. The cover14can be disconnected from the base to permit a user to access the spool16and tension line in the housing. A hex tool mating with the hexagonal opening14acan be used to rotate the cover14relative to the base12to remove or reattach the cover14to the base12.

Turning toFIGS.4and5, the spool16is received and surrounded in the housing10. The spool is coaxially aligned with the cover14and the base12. The spool has an upper flange16band a lower flange16cconnected to ends of the axle16a, which is hollow in the example to receive a sliding retainer17, further details of which are described below.

The upper flange16bdefines a central opening16daligned with the opening14ain the cover14. The central opening16dis shown as being a hexagonal opening having a smaller diameter than the opening14a. The central opening16dleads into an upper end of a tool socket18that extends axially about a second axis and along axis A-A from the upper flange16bto a shoulder16a2extending from an inner surface16a1of the axle16a. Second axis is coaxial with first axis on axis A-A. The socket18is configured to receive a mating tool130(FIG.12). The socket18is configured to prevent relative rotation between the socket18and the tool130relative to axis A-A. Specifically, in the example shown, the socket18is defined as a six-sided bore18athat is configured to receive a six-sided tool, such as an end of a hex key130shown inFIG.12.

Also, the interior of the axle16aand the socket18are in communication with one another and are configured to receive a retainer17and to prevent relative rotation between the retainer17and the spool16. The retainer17includes a lower base17aand an upper protrusion17bconfigured to be received in and mate with the bore18aof the socket18from a lower end of the socket18to prevent relative rotation between the retainer17and the spool16. In the example shown, the upper protrusion17bof the retainer17has a hexagonal profile that is configured for axial reception along axis A-A into and out of the lower end of the bore18aof the socket18. The base17aof the retainer17is configured to engage the shoulder16a2which provides a positive stop to axial movement of the retainer17into the bore18aof the socket18.

The retainer17also defines a central bore17c(FIG.5) extending axially along axis A-A from a lower side of the base17a. In the example shown, the central bore17chas a hexagonal profile to receive and mate with a hexagonal central post15(FIG.4) extending axially along axis A-A and fixed to an upper surface of the mounting flange12bon the inside of the housing10. The engagement between the retainer17and the post15prevent relative rotation therebetween but permits the retainer17to translate along axis A-A relative to the post15.

The retainer17is biased axially along A-A towards the upper flange16bof the spool16with a biasing member19, shown as a spring. As shown inFIGS.6and10, when the bore18aaligns with the protrusion17bof the retainer17and no tool is inserted into the bore18aof the socket18, the retainer17is pushed upward into the bore18ain an engaged configuration, thereby preventing the spool16from rotating relative to the retainer17. Moreover, when the retainer17is in the engaged configuration with the spool16, the retainer17remains rotationally fixed to the post15. Thus, when the retainer17is in the engaged configuration with the socket18, the spool16is rotationally locked relative to the housing10.

As shown inFIG.12, the retainer17is configured to be disengaged from the spool16by inserting a tool130under manual force through holes14aand16dinto the bore18aof the socket18in a direction parallel to the axis A-A to connect the tool130to the socket18to translate the retainer17axially along A-A in the downward direction of the arrow B shown inFIGS.11,12, and13. Once the retainer17is displaced completely below the shoulder16a2, the spool16is rotationally disengaged from the retainer17so that the spool16can be rotated relative to the housing10about A-A using the tool130, as shown inFIG.13. The spool16can be rotated in either of the directions shown by arrows C and D inFIG.12.

When a user is finished rotating the spool16in either directions C or D, the user can align the bore18awith the retainer17so that the tool130can be withdrawn from the bore18ain a direction opposite arrow B inFIG.13while the retainer17seamlessly is reinserted into and engages the bore18ato retain tension in the elongate member and prevent the elongate member from unwinding.

FIG.8shows ends of a tension line20connected to the axle16aof the spool16and where the tension line20is not wound around the axle16aof the spool16.FIG.9shows the tension line20collected in the housing and wound around the axle16aof the spool16.FIG.10shows the device ofFIG.9with the wound tension line20and with the retainer17in its engaged configuration. With the retainer17in the engaged configuration, the spool16is rotationally locked relative to the housing10so that any tension in the tension line20cannot cause the tension line20to be unwound by rotation of the spool16in an unwinding direction. However, as shown inFIG.11, a user can reconfigure the retainer17by inserting the tool130to displace the retainer17from the bore18ato disengage the retainer17from the spool16, which can then permit the user to rotate the spool16to unwind the tension line20fully as shown inFIGS.8and11.

The user can be guided in aligning the bore18ainto the engagement position with the retainer17as follows. The base12includes a plurality of circumferentially spaced protrusions13. The lower flange16cof the spool16defines a plurality of notches or grooves16c1that are configured to mate with the protrusions13when the retainer17is aligned with the bore18aof the socket18(FIG.7). When the user rotates the spool16with the tool130, the engagement of the notches16c1and protrusions13provides haptic feedback to the user which can be felt in the hand of the user through the tool130. The haptic feedback can be used as an indicator to the user that the retainer17is in the engaged configuration and that the tool130can be removed from the socket18without loss of tension in the tension line20.

As shown most clearly inFIG.7, the spool axle16ahas a generally oval cross-sectional shape. The oval shape increases the capstan effect or spool's ability to transfer and maintain tension forces. Also, the axle16adefines diametrically opposed through holes16e, each of which is surrounded by a rounded or filleted rim16ffor strain relief of the elongate member that are configured to extend through the holes. The holes16emay be blind holes to retain a terminated end (e.g., an enlarged or flared end of the elongate member). In other embodiments, the elongate member may extend diametrically through the axle without terminating its ends at the axle16a. Also,FIGS.8and9show the gradual bend of the elongate member20around the curved surface16fthat can provide a strain relief to prevent damage to the elongate member20. The inner edges12a1(FIG.8) of the holes12amay also be rounded to protect the elongate member from abrasion and wear.

FIGS.8and9also show a collection volume21and a pathway between the spool16and the inner surface of the housing10. The collection volume21is defined as the space between the spool16and the interior surfaces of the housing10. As shown inFIGS.8and9, as the tension line20is collected, the collection volume21is filled with the tension line. Eventually, if the entire collection volume21is filled with the tension line20, the spool16cannot rotate any farther to collect additional tension line20.

InFIGS.10and11the adjustment device100is seated or otherwise embedded in a material22, which can be part of an article or may itself be a mounting member of the device100that can be attached to an article102, as shown inFIG.10. The material22may be molded around the housing10. In the example shown, a portion of the base12below the cap14is surrounded by the material22. Two cable routing passageways23are integrated into the material22and are in communication with the holes12a. The passageways23are lined with a cable housing24. Each cable housing24has an inner end (relative to the axis A-A) that is received in a bore12a2formed in the outer side of the base12. Each bore12a2aligns with a corresponding hole12a. The passageways and cable housings23and24extend outwardly (with respect to axis A-A) to outer ends from which the elongate member extends without being surrounded by the material22or cable housings24.

FIGS.14to19show details of a second embodiment of an adjustment device200. InFIGS.14to19elements corresponding to those of device100are shown incremented by “100”. The main differences between device100and device200lie in the construction of the spool116, retainer117, and posts115, between the base112and the cover114. The spool116includes a socket118with a central bore118a. As shown in detail inFIG.17, a plurality of teeth136extend along an inner surface of the axle116aaround the socket118. As shown inFIGS.14and15, the base112includes a stitch flange112b.

The retainer117is shown as a central hub117bsurrounded by an annular rim117a. Four radially extending teeth126extend from the annular rim117a. The rim117ais spaced radially from the hub117bby an annular groove117cthat is configured to receive a lower end of the socket118when the retainer117is engaged with the spool116. The teeth126are spaced 90 degrees around a perimeter of the rim117b. The teeth126are configured to engage the teeth136of the spool116when the retainer117is in an engaged configuration with the spool116, as shown inFIG.18.

The retainer117has a central blind hole117cthat is configured to retain a biasing member119, which urges the retainer axially along B-B towards the socket118. A central post115extends along axis B-B and is configured to support spring119and be received in the blind hole117c.

The retainer117defines four axially extending through holes125that are configured to receive and slide on four corresponding posts115aarranged around central post115. The posts115aextend from the base112parallel to axis B-B (FIG.15) and are arranged in a generally square pattern around the central post115. Each post115aextends through a corresponding spring119a. Each spring119aand119biases the retainer117upward towards the socket118. The arrangement of the four posts115aprevent relative rotation between the retainer117and the base112. The four posts115aare longer than the central post115b. The retainer117is configured to slide axially (parallel to B-B) along posts115aand115bbetween an engaged position and a disengaged position. The springs119aand119burge the retainer117upward towards the teeth of the spool. The teeth of the retainer are configured to engage the teeth of the spool when the notches116c1on the lower flange116cof the spool mate with protrusions113of the base112. When such alignment occurs, the retainer117can engage the teeth136of the spool116, as shown inFIG.18. In an engaged configuration, the teeth126of the retainer117are coupled to the teeth136of the spool116, the retainer117is coupled to the posts115a, and the spool116is rotationally locked and cannot rotate relative to the housing110about axis B-B.

Upon insertion of a tool, such as tool130, into the bore118aof the socket118, the retainer117can be translated along axis B-B down and out of engagement with the teeth136of the spool116, as shown inFIG.19. Once the teeth126of the retainer117are disengaged from the teeth136of the spool116, the spool116can be rotated in either rotational direction about axis B-B, and perpendicular to the base of the housing, by applying a rotational force to the tool.

The spool116has a lower flange116chaving a plurality of notches116c1. Twenty notches116c1are shown in the example embodiment that are spaced equally 18 degrees apart; thus, the spool116can be rotated in increments of 18 degrees. As such, the spool has defined stops that incrementally limit the smallest degree by which it can be rotated before the tool can be removed. Different increments can be similarly implemented by changing the rotational spacing of the notches116c1. Alternatively, the stops can be eliminated from the device.

FIGS.20to22show details of a third embodiment of a tool operated adjustment device300. InFIGS.20to22, elements corresponding to those of device200are incremented by 100. The device300includes the same structure as the device200with the following exceptions. The device300includes a spool216with an upper flange216bthat has sloped gear teeth216b1along its outer perimeter. The spool216has an axle216athat extends along axis C-C. The spool216is configured to rotate about axis C-C. Also, the device300includes a housing210with a cover214that defines an opening214athat leads to a tool socket218for receiving a tool for winding the spool216. As shown inFIGS.21A and22A, the spool216has diametrically opposed holes216eto connect to tension line260routed through openings212ain the base212of the housing210. The device300, however, does not include a retainer, like retainer117, to rotationally lock the spool relative to the housing.

Instead, the device300includes a ratcheting pawl mechanism240that is housed in the housing210and is pivotally coupled to the housing about an axis D-D, which is spaced from axis C-C of the axle216a. The mechanism240is operably configurable between a first configuration in which the mechanism240permits one way rotation of the spool216in a first direction (clockwise inFIG.21) and blocks rotation of the spool216in a second direction (counterclockwise inFIG.21), and a second configuration in which the mechanism240permits the spool216to rotate freely in both the first and second directions. The ratcheting pawl mechanism240is thus capable of maintaining tension in the tension line260when the tool is withdrawn from the socket218.

The ratcheting pawl mechanism240includes a pawl241pivotally coupled to and supported by the housing210. The pawl241is resiliently biased (i.e., with a spring242) in an engagement configuration in which the pawl241is engaged with the teeth216b1of the gear216bto permit rotation of the gear216b, and thus the entire spool216, in the first rotational direction (clockwise inFIG.21), while preventing rotation of the spool216in the second rotational direction (counterclockwise inFIG.21).

The pawl241is connected to a socket218cthat is accessible through an aligned hole214cin the cover214of the housing210. The socket218cis configured to receive a tool, which is preferably the same tool used in socket218. The socket218cis rotationally fixed to the pawl241so that rotation of the socket218cusing the tool can cause corresponding rotation of the pawl241about its axis of rotation D-D. In the example shown inFIG.21, a user wishing to disengage the pawl241from the gear216b, such as for reducing tension in a tension line wound around an axle216aof the spool216, can insert a tool into the second socket218cand rotate the tool counterclockwise inFIG.21. Once the pawl241is disengaged, either the inherent tension in the tension line260will cause extension of the tension line260to reduce tension and rotated the spool216in the second direction, or the user can use a second tool in the socket218to rotate the spool216in the second direction. The user can choose to loosen the tension line260by turning the tool in the second socket218cin the counterclockwise direction briefly then can turn the tool back in the clockwise direction to re-engage the pawl241with the teeth216b1for partial or incremental release. Alternatively, the user can turn the tool in the counterclockwise direction and leave it turned away until tension is fully released.

Turning now toFIGS.23A-23C, another embodiment of a tool operated adjustment device2000is shown. The device2000includes a housing with a spool2016having an axle2016a, as well as a spring-biased pawl2041, as previously described with respect to device300. Distinctions in adjustment device2000from device300include the following. The device2000includes a drive gear2070mounted on a parallel axle2074to axle2016a, and the spool2016is rotationally fixed relative to a driven gear2072meshing with the drive gear2070. The drive gear2070includes a control port2018for receiving the tool. When the pawl is released (discussed below) and the tool is rotated, the drive gear drives rotation of the driven gear and the spool.

In this exemplar embodiment shown, the drive gear2070has twice as many gear teeth as the driven gear such that the drive gear can drive the rotation of the spool in a 2:1 ratio. Any other suitable ratio can be provided between the gears. Alternatively, the drive gear2070can have fewer teeth to provide gear reduction and resulting finer adjustment of the driven gear. Such gear transmissions described in this embodiment are intended for application within any of the device within the scope of adjustment devices described herein.

In addition, in distinction from adjustment device300, the spring-biased pawl of device2000engages the drive gear2070. The pawl2041is manually releasable by rotating a portion of the pawl or knob2076connected thereto extending through the upper end of the cover2014such that only a single tool is required to operate the device. Such pawl release mechanism may be similarly used in association with device300. The pawl2041is operably configurable between a first configuration in which the mechanism permits one way rotation of the spool2016in a first direction and blocks rotation of the spool2016in a second direction, a second configuration in which the mechanism permits one way rotation of the spool2016in the opposite direction as the first configuration and blocks rotation of the spool2016in the opposite direction as the first configuration, and a third configuration in which the mechanism permits the spool2016to rotate freely in both the first and second directions.

Referring now toFIGS.24A and24B, another embodiment of a tool operated adjustment device2100is shown. The device2100includes a housing2110with a spool2116provided with an axle2116a. The housing2110includes an interior ring of gear teeth2180. A central star gear2182is coaxially situated over the spool2116. A central control port2118is provided in the upper end of the housing2110and into the star gear2182. A carrier plate2184is rotationally coupled with the spool2116. A set of three planet gears2186are rotatably mounted on pins on the carrier plate2184in an equidistantly spaced relationship. The planet gears2186are engaged with the gear teeth2180of the housing and the star gear2182. Three pawls2188are radially arranged on the retainer plate2184between the planetary gears2186and include a first portion2188afor engagement with the star gear2182and second portion2188bdefining a camming ramp that extends within the control port2118. The pawls2188are provided with a compression spring2190to bias the first portion2188ato interfere with the star gear2182and prevent rotation of the planetary gears2186when no tool is present in the control port2118. When the tool is inserted into the control port2118, the tool forces against the camming ramps2188bof the pawls to displace the second portion of the pawls away out of interference with the star gear2182so that the planetary gears2186can rotate and allow the spool2116to wind within the housing2114. The planetary gear system provides mechanical advantage to the system. The planetary gear system described in this embodiment is intended for application within any device within the scope of adjustment devices described herein.

FIGS.25to31shows details of a fourth embodiment of a tool operated adjustment device400. The adjustment device400is configured for use with a tension line strap (not shown). The device400includes a generally cylindrical housing410that extends along a central longitudinal axis E-E from a first base end410ato a second upper end410b. The housing410defines two diametrically opposite elongated tension line slots412through which tension line straps can extend into and out of the housing410.

A tool socket414is located at a first end410aof the housing for rotating a spool424(FIGS.28and29) (aligned with the slots412) housed inside the housing410. The first end410aof the housing410is connected to a retaining ring with a threaded connection. The retaining ring413retains the tool socket element414at the first end410aof the housing410. A release button416is located at the second end410bof the housing410that is opposite the first end410aof the housing410. The button416is configured to translate axially relative to the housing410along axis E-E, but the button416cannot rotate relative to the housing410due to the interlocking shape of the button416and the hole in the second end410bof the housing410that the button416extends through. The release button416is biased outwardly with respect to the second end410bof the housing410. A cover418is pivotally connected to the second end410bof the housing410and is configured to rotate about axis E-E parallel to central longitudinal axis E-E. When the button is not in use, the cover can be rotated over the button to conceal and protect the button from inadvertent actuation. When the button416is to be used, the cover418can be rotated about axis E-E to reveal the button, as shown inFIGS.24and30.

The body410includes a tool holder420that extends from an elongate outer side of the housing410. The tool holder420retains a tool422that is receivable in the tool socket414. The tool422shown is a hex key.

FIGS.26,27, and29show additional details of the spool424and ratcheting release mechanism426housed inside the housing410. The spool424includes a first flange415, a second flange417, and two elongated members419rigidly connected at their ends to the first and second flanges415,417. The tool socket414is rotationally fixed to the first flange415of the spool424. In the embodiment, the first flange415is integrally formed with the tool socket414, though this is not a requirement. The flanges415and417connect to the elongated members419so that there is an elongated gap419abetween the elongated members to receive and retain a tension line strap. The elongated members419have an overall oval profile for at least the same reasons as the oval profile of the axle16aof device100described herein. The entire spool424is configured to rotated in unison about axis E-E.

The second flange417of the spool is configured to connect to the ratcheting release mechanism426. Specifically, notches417aare formed along a peripheral edge of the second flange417. The notches are configured to engage pins421that rotationally couple the second flange417to the ratcheting release mechanism426as described in greater detail below.

The ratcheting release mechanism426includes a shaft coupler423, a ratcheting disc425, the release button416, a spring427, and a spring retainer429. The shaft coupler423is an annular member having an inner cylindrical surface defining an interior space and an outer cylindrical surface that is configured to rotate in unison with the spool424about inner surface of the housing410. As shown in greater detail inFIG.31, the second flange417of the spool424is received and seated in an inner side (relative to central axis F-F) of the interior space of the shaft coupler423. The second flange417is pivotally fixed to the shaft coupler423with the pins421so that the entire spool424and shaft coupler423rotate about axis E-E in unison (FIGS.25and27).

The spring427, spring retainer429, and ratcheting disc425are also disposed in the interior space of the coupler423. The spring427is positioned between the second flange417of the spool424and the spring retainer429. The ratchet disc425is positioned between the spring retainer429and the push button416. The push button has pins416athat extend through the ratchet disc425and spring retainer429to rotationally fix them all to one another so they all remain rotationally fixed together and thus remain rotationally fixed relative to the housing410due to the fact that the button416is rotationally fixed relative to the housing410.

The ratchet disc425, spring retainer429, and push button416are configured to translate along axis E-E within the interior space of the shaft coupler423. The spring427biases the ratchet disc425, spring retainer429, and push button416outward (relative to axis F-F). The inner cylindrical surface of the outer side (relative to the axis F-F) of the coupler423has inner teeth423athat are configured to engage ratchet pawls425aof the ratchet disc425when the push button416is in a first configuration in which the button extends outward from the second end410bof the housing410, as shown inFIGS.32and33.FIG.33shows ratchet disc425engaged with the inner teeth423aof the shaft coupler423. When the button416is pressed inward toward axis F-F, as shown inFIGS.30and31, the ratchet disc425is translated inwardly against the bias of the spring427(which is compressed), which disengages the ratchet pawls425afrom the inner teeth423aof the shaft coupler423. When the pawls425aof the ratchet disc425are disengaged from the inner teeth423a, the user can rotate the spool424in either the first or the second direction about the axis E-E directly using the tool422in the tool socket414. Also, if tension has been built up in a tension line connected to the spool424, pressing on the release button416will cause the spool424to unwind in the second rotational direction about axis E-E to reduce tension in the tension line.

The pawls425aof the ratchet disc425, when engaged with the inner teeth423aof the coupler423, permit the spool424to rotate in a first rotational direction about axis E-E when the socket414is rotated using the tool422, while preventing the spool424from rotating in a second rotational direction opposite the first direction. When the tool is released or withdrawn from the tool socket414, the pawls425aretain tension in the tension line. The tension can be released by disengaging the pawls425afrom the inner teeth423aof the shaft coupler423by pushing on the release button416.

Turning now toFIGS.34A-34C, a modification to the fourth embodiment is provided which facilitates collecting tension line at the exterior of the housing; i.e., to effectively make the housing of the adjustment device into a secondary spool. (The inner ratcheting assembly is the same as in adjustment device400and will not be further described here.) The modification adjustment device400′ includes the following. As shown inFIGS.34A-C, the adjustment device400′ bolts together, defining lateral bosses460′ on diametrically opposing sides of the housing410′. Gear teeth462′ are provided fixed to one end of the exterior of the housing410′. A removable cap464′ is provided that covers and exposes the gear teeth462′.

Referring toFIGS.34D-34F, a removable outer ratcheting assembly470′ is provided for coupling with the adjustment device400′. The ratcheting assembly470′ includes first and second ratchet plates472a′ and472b′, a release handle474′, a spring476′, first and second pivot bars478a′ and478b′, and optionally a spacer480′ with snap-fit receiver482′ for a tool402′. The adjustment device is assembled into recesses484′,486′ within the ratchet plates472′ and spacer480′, with the bosses460′ registering in the recesses and fixing rotation of the device relative to the plates. The ratchet plates472a′,472b′ and handle474′ are assembled about the adjustment device400′ with screws481′. The release handle474′ extends in a u-shape into ratchet plates and includes a pawl488′ at one end. The pawl488′ is biased by the spring476′ to interfere with the gear teeth462′. Referring toFIG.34F, while the pawl488′ is engaged, as the inner ratcheting assembly is activated with the tool402′ inserter and rotated within control port418′ (FIG.34E), the flexible elongate member490′ is wound first about the interior spool416′; then, once the interior spool is full, the elongate flexible member490′ is wound about the exterior of the housing. The pivot bars478a,478bprevent unwinding of the flexible elongate member490′. Pulling on the release handle474′ relative to the ratchet plates424a′ and472breleases the pawl488′ from interference with the gear teeth462′ so that the ratchet assembly can rotate relative to the adjustment device and allow unwinding of the flexible elongate member490′.

FIGS.35to38show details of a fifth embodiment of a tool operated adjustment device500. The device500has substantially corresponding structure to device400. One difference between device500and device400lies in the fact that the spool516of the device500is constructed to wind a tension line lace or cable rather than a strap. Thus, a smaller spool516is utilized. In addition, the housing510and entry/exit ports530,532are correspondingly smaller as well, and a stitch flange511is provided to the housing for integration of the device into an article, such as soft goods or a textile-based application.

An additional feature of device500includes a dial534rotationally fixed relative to the spool516and accessible from outside the housing. The dial534allows a user to collect slack or loose cable or lace before a tool is inserted into the control port514. The dial534offers minimal mechanical advantage, but allows the user to slide a finger, palm, or other surface across the dial to collect the loose lace then use the tool to increase the tension under the mechanical advantage of the tool (and/or any gears that may be integrated into the device, as described above).

Prior artFIG.39Aillustrates that prior art tensioning device that include an integrated line tensioner are bulky devices and protrude when applied to wearable articles on the human body. The larger profile of the prior art systems610and611can concentrate an impact force on the portion of the body to which the systems610and611are attached if a user falls or is impacted in that area of the user's body. In addition, the larger size can be aesthetically displeasing or unsuitable for certain wearable applications. By way of comparison, the adjustment devices620shown inFIG.39Bhave a lower profile. This is permitted, at least in part, because they use a separable tool rather than a line tensioner having an integrated-force applier; thus, they can be made smaller in size and better integrated with wearable articles. Further, in the event of a fall, force on the wearer is minimized as a result of the smaller size. In addition, by requiring use of a separate tool for tension and/or release, they are optimized to prevent inadvertent adjustment.

FIGS.40-66show various uses of adjustment devices into various exemplar articles. Such articles include wearable articles, in which the adjustment device operates to facilitate the fit of the article; sporting articles requiring application of tension, and utility articles requiring application of tension. It will be appreciated that adjustment device620of the systems640may take the form of any of the embodiments of an adjustment device described herein and is not limited to the schematics shown inFIGS.40-66. Furthermore, it is appreciated that the fields and applications shown and briefly described herein are not intended to be exhaustive or limiting but are merely examples.

FIGS.40-42shows fit systems620applied to a prosthetic socket700. For the socket shown inFIGS.40-42, an adjustment device640is coupled to the socket to apply or release tension on a cable645extending about all or a portion of a circumference of a prosthetic socket. For example, the device may be adjusted to tension the cable645to draw struts648a,648b,648c,648dof the socket radially inward or release tension to allow the struts to flex radially outward. Similarly, fit systems620could be applied to a prosthetic socket700to draw two sections or regions of the prosthetic socket700closer together or allow them to flex apart. Applying or relieving tension in the tension lines can enlarge or reduce the opening of the prosthetic or change the distribution of forces to adjust the fit of the prosthetic to a user. As shown inFIGS.41and42, each system620shown inFIG.40includes one adjustment device640connected to the cable645banded about the prosthetic socket700. As shown inFIG.42, a tool630is required to adjust tension to prevent inadvertent adjustment or limit adjustment to a prosthetist.

Referring toFIG.43, the adjustment device of the fit system may be mounted to the shell of the helmet710or may be left free to be positioned along the strap650b′ at an intermediate position between the sides of the helmet.

Turning toFIG.44, multiple fit systems620are connected to a ski boot720. The straps are banded around a leg portion and a foot portion of the boot and the adjustment devices of the straps may be mounted directly to the leg and foot portions of the boot.FIG.45shows fit systems620connected to snowboard boots730. Straps of the systems620are banded about the leg portion of the snowboard boots with the adjustment device640mounted directly to the boot. Also, straps of the fit system620are shown connected to the snowboard and include adjustment devices640mounted to the snowboard straps which can be used to adjust the connection of the snowboard boots to the snowboard.FIG.46shows a fit system620connected to a skate740, specifically an ice skate. The adjustment device640of the fit system620is mounted directly to the skate while the tension line is banded about the skate.

FIG.47shows an embodiment of a fit system620connected to a sandal750. The adjustment device640of the fit system620is mounted to one of the sandal straps while the tension line takes the place of a sandal closure strap.FIG.48shows a fit system620connected to a shoe760. The adjustment device640of the system620is mounted to the shoe and the strap extends across the tongue of the shoe.FIG.49shows a fit system620connected to a boot770, where the fit system is arranged identically to the system shown inFIG.46used with a skate740.FIG.50shows a fit system620with an adjustment device that is embedded into an upper of a shoe780with laces partially concealed by the upper (shown in broken lines) and laces that are visible across a tongue of the shoe.

FIG.51shows an embodiment of a fit system620used for an adjustable strap of a day pack790application. The tension line of the system620is connected to the day pack and the adjustment device640is not directly mounted to the day pack, but is spaced therefrom.FIG.52shows a fit system620used for an adjustable strap of a bag or backpack800(e.g., a camping backpack). The tension line of the system620is connected to the backpack and the adjustment device640is not directly mounted to the backpack but is spaced therefrom.

FIGS.53and54show uses of line tensioning systems620.FIG.53shows fit systems620used as straps of a suspended tent810. Each strap is connected to a corresponding adjustment device640. Each strap is configured to connect at one end to a tent and an opposite end to another structure (such as a tree) to suspend the tent above the ground. The line tensioning systems620may also be used for other suspension applications, such as mountaineering, rock-climbing, and rappelling. Similarly, the line tensioning system620may be used to tension sporting nets, such as for tennis, badminton, volleyball, table tennis, etc., and may be provided with the equipment therefor.FIG.54shows line tensioning systems620used as cargo tie down straps820connected to a truck bed. The line tensioning systems described herein can also be used as closures in carry-alls, suitcases, duffel bags, sport bags, and thus may be incorporated into such articles in accord with the intended scope herein.

FIGS.55-59show fit systems620applied to protectable wearable articles utilized in the field of motorsports. Specifically,FIG.55shows fit systems620applied to a protective vest900that can be used to adjust the fit of the vest to a user.FIG.56shows fit systems620applied to a protective suit910. The fit systems can be used to adjust the fit of the protective suit to a user's body at the locations shown inFIG.56.FIG.57shows a fit system620applied to a motorcycle boot920. As shown inFIG.57, two straps are banded about the boot: one strap banded about a leg portion of the boot and one strap banded about the foot. Separate adjustment devices640may be provided for each strap to independently tension each strap.FIG.58shows fit systems620applied to protective knee pads930where the strap is configured to be banded about the knee of a user and the adjustment device640can be used to adjust the fit of the straps.FIG.59shows a fit system620applied to protective pants940for adjusting the waist of the pants to fit a waist of a user.

FIG.60shows fit systems620applied to a prosthesis1000where the tension lines are straps banded about the socket of prosthesis.FIGS.61-64show various uses of the fits systems620in the field of orthotics (braces) for bracing bones and joints.FIG.61shows a fit system620utilized in an ankle orthosis1010. As shown inFIG.61, one strap is banded about a leg portion of the brace and one strap is banded about a foot portion of the brace. The adjustment device640of the fit system620is mounted to the device and controls tension in the two straps.FIG.62shows a fit system620applied to a back brace1020for thoracic lumbar sacral orthosis (TLSO) application. The strap of the system620is banded about the back and torso of the user and the adjustment device640is positioned over a user's chest for access to the user.FIG.63shows fit systems620applied to a knee brace1030or knee orthosis. One fit system is banded about the leg above the knee, while another fit system is banded about the leg below the knee. The adjustment devices640of the fit systems620can adjust tension in the straps to fit the straps to the user's leg.FIG.64shows fit systems620applied to a post-operative knee brace1040or knee immobilizer. The fit systems620are shown banded about the user's lower leg.

FIGS.65and66show fit systems620utilized in the field of clothing accessories and clothing. As shown inFIG.65, the fit system620is used as a belt for a pair of pants, which may be integrated into the pants1100. For example, the adjustment device640may be mounted to the pants with the strap of the fit system620banded about the waist of the pants.FIG.66shows the fit system620in the form of a belt1110. Where the fit system620is worn about the body, it is preferred to incorporate a tension limiter. However, in certain applications where the fit system620is intended to apply tension around the body, such as a tourniquet, it will be appreciated that the tension device of the fit system620would omit a tension limiter.

There have been described and illustrated herein several embodiments of a tension device, fit systems using the tension device, and a method of using the tension devices and fit systems. While particular embodiments of the invention have been described, it is not intended that the invention be limited thereto, as it is intended that the invention be as broad in scope as the art will allow and that the specification be read likewise. Thus, with respect to any embodiment, where a hex-shaped control port or similar structure has been described and corresponding hex-shaped tool for insertion therein and operation on the adjustment device, it is appreciated and intended that the control port or similar structure and working end of the tool can be any cooperative shapes that permit application of a torque. Thus, by way of example only, they can both have cross-sectional shapes that are polygonal, both have interfering but different cross-sectional polygonal shapes, or even have shapes with a combination of curves and/or at flat, provided that both the port and tool are not completely circular. Further, while particular tension line types have been disclosed, it will be appreciated that other tension line types may be used as well. For all of the embodiments, the line tensioning systems may be made from a plastic, metal, or a combination plastic and metal components. In addition, while particular types of plastics have been disclosed for parts of the embodiments, it will be understood that other suitable types of plastics can be used. For example, and not by way of limitation, acrylic and polycarbonate may be used. Moreover, while particular configurations have been disclosed in reference to housings for the tension devices, it will be appreciated that other configurations could be used as well. It will therefore be appreciated by those skilled in the art that, yet other modifications could be made to the provided invention without deviating from its scope as claimed.