HK1188093A - Reel based closure system - Google Patents

Description

Reel-based closure system

The application is filed in 2005 at 10/31 under the name: a divisional application of chinese patent application 200580043345.4 (PCT/US 2005/039273) of "reel-based closure system".

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation-in-part application of pending U.S. patent application No.10/459,843 filed on 12.6.2003, this application is a continuation-in-part application of pending U.S. patent application No.09/993,296 filed 11/14/2001, this application is a continuation-in-part application of abandoned U.S. patent application No.09/956,601 filed on 9, 18, 2001, this application is a continuation of U.S. patent application No.09/388,756 filed on day 9, 2 1999, U.S. patent application No.09/388,756 is now U.S. patent No.6,289,558, which is a continuation of U.S. patent application No.09/337,763 filed on day 22, 6, 1999, U.S. patent application No.09/337,763 is now U.S. patent No.6,202,953, which is a continuation of U.S. patent application No.08/917,056 filed on day 22, 8, 1997, and U.S. patent application No.08/917,056 is now U.S. patent No.5,934,599. This application also claims the benefit of U.S. provisional patent application No.60/623,341 filed on day 10/29 in 2004 and U.S. provisional patent application No.60/704,831 filed on day 8/2 in 2005.

Is included in the present application by reference

This application is incorporated herein by reference as if it were filed on 12.6.2003 in U.S. patent application No.10/459,843; U.S. patent application No.09/993,296, filed 11/14/2001; 09/956,601, filed on 9/18/2001; U.S. patent No.6,289,558 issued 9, 18, 2001; U.S. patent No.6,202,953 issued 3/20/2001; U.S. patent No.5,934,599 issued on 10.8.1999; U.S. provisional patent application No.60/623,341, filed on day 10/29 in 2004 and U.S. provisional patent application No.60/704,831, filed on day 8/2 in 2005, all of which are incorporated herein by reference.

Background

Technical Field

The present invention relates to closure systems for use in conjunction with any of a variety of applications, including clothing, such as low friction lacing systems for footwear, that provide balanced fastening pressure on a wearer's foot.

Background

There are many mechanisms and methods currently available for fastening a shoe or boot to a person's foot. The conventional method involves passing the straps through two parallel rows of eyelets connected to opposite sides of the footwear in a zig-zag arrangement. The shoe is tied by first pulling the opposite ends of the lace through the eyelets to pull the two rows of eyelets towards the midline of the foot and then tying the ends into a knot to maintain tension. A number of disadvantages are associated with this type of lacing system. First, the lace does not adequately distribute the tightening force along the length of the area through which it passes due to the friction between the lace and the eyelets, such that some portions of the lace are slack and other portions are tight. As a result, the more tightly pulled portion of the footwear is stretched more tightly around certain portions of the foot, particularly the ankle portion closer to the ends of the straps. This is uncomfortable and can adversely affect performance in certain sports.

Another disadvantage associated with conventional ties is that it is often difficult to untie or redistribute the tension on the tie because the wearer must loosen the tie from each of the numerous eyelets through which it passes. The lace cannot be easily loosened by merely untying the knot. Even when the knot is untied, friction between the lace and the eyelet often keeps the toe portion, and sometimes a large portion of the foot, taut. Thus, the user must typically loosen the lace from each eyelet one by one. This is particularly troublesome if the number of eyelets is large, such as in skate boots or other specialized high performance footwear.

Another fastening mechanism includes snaps that snap together to fasten the shoe to the foot of the wearer. Typically, three or four or more clasps are provided on the upper of the shoe. The clasps can be quickly snapped together and pulled apart to tighten and loosen the shoe on the wearer's foot. Although buckles can be easily and quickly tightened and loosened, they still suffer from certain drawbacks. Specifically, the closure isolates the closure pressure across three or four points along the wearer's foot corresponding to the location of the closure. This is not appropriate in many situations, such as in the case of athletic boots where the wearer desires a line of force that is evenly distributed along the length of the foot. Another disadvantage of buckles is that they are generally only useful for boots of hard plastic or other hard materials. For softer boots, the buckles are less practical, such as skates or snowboard boots.

There is thus a need for a footwear fastening system that does not suffer from the above-mentioned disadvantages. Such a system should automatically distribute the lateral tightening force along the length of the wearer's ankle and foot. The tightness of the shoe should be suitable for easy loosening and incremental adjustment. The fastening system should be tightly closed and not loose for continued use.

Disclosure of Invention

In accordance with one aspect of the present invention, a footwear lacing system is provided. The footwear member of the system includes first and second opposing sides configured to fit the foot. A plurality of lace guide members are disposed on opposite sides. The lace is guided by the guide member, and the lace is rotatably coupled to the spool, which is rotatable in a winding direction and an unwinding direction. A tightening mechanism is connected to the footwear member and coupled to the spool, the tightening system including a control for winding the lace on the spool to apply tension to the lace to draw the opposite edges together. The safety device is movable between a fastening position in which the spool cannot rotate in the unwinding direction and a release position in which the spool can rotate freely in the unwinding direction.

In one embodiment, the lace may be slidably disposed about the guide members to provide a dynamic fit as the foot moves within the footwear. The guide member may be substantially C-shaped in cross-section.

Further, the tightening mechanism is a rotatable spool configured to receive the lace. According to one embodiment, the knob rotates the spool, thereby winding the lace onto the spool. In some embodiments, rotating the knob in the unwinding direction releases the spool and allows the lace to unwind. A safety device, such as a lever, may be mounted that selectively allows the knob to be rotated in the unwinding direction to release the spool. Alternatively, the safety device may be a rotatable release that is separately rotated from the knob to release the spool.

In some embodiments, a footwear lacing system is associated with footwear having a first opposing edge that is configured to extend from an edge of the footwear, across a superior midline of the footwear, and to an opposing edge of the footwear. Likewise, the spool may be mounted on the first opposing edge.

In one embodiment, the ligaments are formed from polymeric fibers.

In accordance with another aspect of the footwear lacing system, a footwear closure system has an upper with a lateral side and a medial side, the closure system including at least a first lace guide associated with the lateral side of the upper and at least a second lace guide associated with the medial side of the upper, and each of the first and second lace guides includes a lace channel along which a lace can slidably extend. Further, a footwear tightening reel is provided on the footwear, the tightening reel retracts the lace, advancing the first lace guide toward the second lace guide to tighten the footwear, and a lock is movable between a coupled position, wherein when the lock is engaged, the lock only allows the reel to rotate forward, and an uncoupled position, wherein when the lock is disengaged, the lock allows the reel to rotate in the opposite direction.

Embodiments also include a closed loop strap, wherein the strap is permanently mounted within the spool. Accordingly, at least the first and second lace guides each include an open channel for receiving a closed loop lace.

According to another embodiment of a footwear lacing system, a spool and lacing unit are provided for use with a footwear lacing system that includes a spool having ratchet teeth disposed about a periphery thereof, the ratchet teeth configured to interact with a pawl to inhibit relative rotation of the spool in at least one direction, and a lace securely coupled to the spool. Alternatively, the lace may be formed of a relatively low elasticity, relatively high tensile strength, smooth textured polymer. Alternatively, the tether may be formed from a multi-strand polymer cable. Alternatively, the tether may be formed from a multi-strand metal cable, preferably having a smooth textured polymeric outer shell.

Drawings

FIG. 1 is a side view of a sports boot including a lacing system configured in accordance with the present invention;

FIG. 2 is a front view of the athletic boot shown in FIG. 1;

FIG. 3 is a schematic perspective view of the lacing system of the athletic boot shown in FIG. 1;

FIG. 4 is a top view of the multi-piece guide member;

FIG. 5 is a side view of a athletic boot that includes an ankle support band;

FIG. 6 is a front view of a sports boot including an intermediate lace guide member disposed adjacent the tongue of the boot;

FIG. 7 is a front schematic view of a foot portion of a boot having a plurality of lace locking members disposed along lace channels;

FIG. 8 is a front view of the instep portion of the boot;

FIG. 9 is an enlarged view of the area within line 9 of FIG. 8;

FIG. 10 is a top view of an alternative embodiment of a lace guide;

fig. 11 is a side view of the lace guide of fig. 10;

FIG. 12 is a top view of the lace guide shown in FIG. 10 installed in a boot cover;

FIG. 13 is a cross-sectional view of the lace guide and boot cover taken along line 13-13 of FIG. 12;

FIG. 14 is a side view of a second embodiment of a tie-down mechanism.

Figure 15 is a top view illustrating one embodiment of the footwear lacing system of the invention attached to a shoe shown in phantom.

Figure 16 is a side elevational view of a shoe having another embodiment of the footwear lacing system of the invention attached thereto.

Fig. 17 is a side elevational view of a footwear having yet another embodiment of the footwear lacing system of the invention attached thereto.

Fig. 18 is a perspective view of an embodiment of a lacing system having a protective element.

Fig. 19 is a side elevational view of the lacing system of fig. 18, showing the protective elements.

Fig. 20 shows a perspective view of an embodiment of a lacing system with an alternative protective element.

FIG. 21 is an exploded perspective view of an embodiment of the self-winding tie-down mechanism.

Fig. 22 is a top view of the mechanism shown in fig. 21.

FIG. 23 is a cross-sectional view of the mechanism shown in FIG. 22, taken through line A-A.

FIG. 24 is a top view of one embodiment of a portion of a self-winding tie-down mechanism.

FIG. 25 is a cross-sectional view of the mechanism shown in FIG. 24, taken through line B-B.

FIG. 26 is a perspective view of one embodiment of a portion of a self-winding tie-down mechanism.

FIG. 27 is a perspective view of an embodiment of a spring assembly used in some embodiments of the self-winding tie-down mechanism.

Figure 28 is a schematic plan view illustrating one embodiment of a multi-zone lacing system.

Fig. 29A-D are perspective, end, top, and side elevation views of one embodiment of a dual layer lace guide used in embodiments of multi-zone lace systems.

Figures 30A-D are perspective, end, top, and side elevation views of one embodiment of a double layer transfer lace guide for use in embodiments of a multi-zone lacing system.

Figure 31 is an exploded bottom perspective view of one embodiment of an upper structure.

Figure 32 is an exploded top perspective view of one embodiment of an upper structure.

FIG. 33 is a detailed view of an embodiment of a fastening mechanism for the upper structure.

FIG. 34 is a side elevational view of an embodiment of the assembled upper.

Fig. 35 is a perspective view of a lace guide that includes a slot for some embodiments of a lacing system.

Fig. 36 is a perspective view of a lace guide that includes hooks for use in some embodiments of the lacing system.

Figures 37A-C are schematic views of an embodiment of a lacing system configured to fold the lace in half at the appropriate portions.

Figures 38A and 38B are side elevational views of one embodiment of a component of a lacing system.

FIG. 39 is an exploded top perspective view of one embodiment of a tie-down mechanism.

FIGS. 40A-40C are different views of a component of the tightening mechanism.

FIG. 41 is a top perspective view of one component of the tightening mechanism.

Figures 42A-42E are different views of a component of the tightening mechanism.

FIGS. 43A and 43B are different views of a component of the tightening mechanism.

FIGS. 44A and 44B are top views of one embodiment of a tightening mechanism, shown engaged in FIG. 44A and disengaged in FIG. 44B.

FIGS. 45A and 45B are cross-sectional side views of one embodiment of a tie-down mechanism.

FIG. 46 is a cross-sectional top perspective view of one embodiment of a cinching mechanism.

Fig. 47A-47C are different views of one embodiment of a lacing system installed on a piece of footwear.

FIG. 48A and FIG. 48B are side elevation views of one embodiment of a fastening mechanism.

FIGS. 49A and 49B are front and back perspective views of a component of the tightening mechanism.

Fig. 50A and 50B are different views of one embodiment of a lacing system secured to a piece of footwear.

FIG. 51 is a top perspective view of the components of the lacing system.

Fig. 52A and 52B are front and perspective views, respectively, of one embodiment of a tie-down mechanism.

FIG. 53 is an exploded top perspective view of one embodiment of a tie-down mechanism.

Fig. 54A-54K are different views of an element that may be included in an embodiment of a fastening mechanism.

FIGS. 55A-55F are different views of the assembled components of the cinching mechanism embodiment.

Figures 56A-56F are different views of the assembled components of the cinching mechanism embodiment.

FIGS. 57A-57F are different views of a component of an embodiment of a tie-down mechanism.

FIG. 58 is a bottom perspective exploded view of one component of the embodiment of the tightening mechanism.

FIGS. 59A and 59B are cross-sectional side views of components of an embodiment of a tie-down mechanism.

Detailed Description

Referring to FIG. 1, one embodiment of an athletic boot 20 made in accordance with the present invention is disclosed. The athletic boot 20 generally comprises a skate or other athletic boot that is secured to the wearer's foot using a lacing system 22. The lacing system 22 includes a lace 23 (FIG. 2) that passes through the boot 20 and is connected at an opposite end to a tightening mechanism 25, as described in detail below. As used herein, the terms lace and cable are intended to be the same unless otherwise specified. Lace 23 is a low friction lace that slides easily through boot 20 and automatically balances the tightening of boot 20 over the length of the lacing area that typically extends along the ankle and foot. Although the invention will be described with reference to a skate boot, it will be appreciated that the principles discussed herein may be readily applied to any of a wide variety of footwear, particularly sports shoes or boots suitable for snowboarding, roller skating, skiing and the like.

The boot 20 includes an upper 24 that includes a toe portion 26, a heel portion 28, and an ankle portion 29 that surrounds the wearer's ankle. The instep portion 30 of the upper 24 is interposed between the toe portion 26 and the ankle portion 29. The instep portion 30 is configured to fit over the medial arch of a wearer's foot between the ankle and the toes. In the skating embodiment, a blade 31 (shown in phantom) extends downwardly from the bottom of the boot 20.

Figure 2 is a front elevational view of the boot 20. As shown, the top of the boot 20 generally includes two opposing closure edges or two lids 32 and 34 that partially cover a tongue 36. Generally, the strap 23 can be tightened to draw the lids 32 and 34 together and to tighten the boot 20 onto the foot, as described in detail below. Although the inner edges of the lids 32 and 34 are shown spaced apart a distance, it will be appreciated that the lids 32 and 34 may also be sized to overlap when the boot 20 is fastened, as is known for example for ski footwear. Accordingly, references herein to drawing the opposite edges of footwear together refer to the portion of the footwear that is located on the lateral side of the foot. Thus, this reference is common to footwear that can remain separated from the edges even when tightened (e.g., tennis shoes), and to footwear that can overlap with the edges when tightened (e.g., certain ski boots). In both types of footwear, the tightening is achieved by drawing the opposing edges of the footwear together.

Referring to fig. 2, the tongue 36 extends rearwardly from the toe portion 26 toward the ankle portion 29 of the boot 20. The tongue 36 preferably has a low friction top surface 37 to facilitate sliding of the covers 32 and 34 and the lace 23 over the surface of the tongue 32 when the lace 23 is tightened. The low friction surface 37 may be formed integrally with the tongue 32 or may be attached to the tongue 32 by, for example, adhesive, heat bonding, stitching, etc. In one embodiment, surface 37 is formed by adhering a layer of flexible nylon or polytetrafluoroethylene to the top surface of tongue 36. The tongue 36 is preferably made of a soft material, such as leather.

The upper 24 may be made from any of a number of materials known to those skilled in the art. In the case of snowboard boots, the upper 24 is preferably made of a soft leather material that is adapted to fit the shape of a human foot. For other types of boots or shoes, the upper 24 may be made of a hard plastic or a soft plastic. It is also contemplated that upper 24 may be made from any of a variety of other well-known materials.

As shown in fig. 2, strap 23 is threaded in a criss-cross arrangement along the midline of the foot between two generally parallel rows of edge retaining members 40 disposed on covers 32 and 34. In the illustrated embodiment, the edge retaining members 40 are each comprised of a strip of material that wraps around the top and bottom edges of the lids 32 and 34 to define a space in which the guide 50 is disposed. During tightening and loosening of the lace 23, the lace 23 slidingly passes through the guides 50, as described more fully below. In the illustrated embodiment, there are three edge retainers 40 on each lid 32, 34, although the number of retainers 40 can vary. In some embodiments four, five or six or more retaining members 40 may be adapted to be located on each side of the boot.

In some boot designs, a pair of opposing lace guides can "bottom out" and contact each other during tightening before the portion of the boot is properly tightened. Further tightening of the system does not tighten the site further. Conversely, other portions of the boot that may have been appropriately sized will continue to tighten. In the embodiment shown in fig. 2, the edge-holding members 40 are each composed of a strip of material wound around the guide 50. Additional adjustability may be achieved by providing releasable attachment means between the retaining members 40 and the corresponding shoe cover 32 or 34. In this manner, the edge retaining members 40 can be laterally offset from the midline of the foot to increase the distance between opposing lace guides.

One embodiment of an adjustable edge retainer 40 can be easily constructed that will look similar to the structure disclosed in fig. 2. In an alternative embodiment, the first end of the strip of material is attached to the corresponding lid 32 or 34 using conventional means, such as rivets, stitching, adhesives, or other means known in the art. As shown, the strip of material is wrapped around the guide 50 and folded back over the outside of the respective lid 32 or 34. Rather than sewing the top end of the strip material to the cover, the corresponding surface between the strip material and the cover may have releasable engaging formations, such as hook and loop formations (e.g.,) Or other releasable engagement locks or clamps that allow for lateral-to-medial adjustment of the position of the guide 50 relative to the edge of the corresponding cover 32 or 34.

Guide 50 may be connected to covers 32 and 34 or other isolated portions of the shoe in any of a variety of ways, as will be appreciated by those skilled in the art in view of the disclosure herein. For example, retaining member 40 may be eliminated and guides 50 sewn directly to the surface of cover 32 or 34 or to the opposite edge of the upper. Stitching the guide 50 directly to the cover 32 or 34 advantageously allows for optimal control of the force distribution along the length of the guide 50. For example, when lace 23 is under a relatively high level of tension, guides 50 may tend to require bending, and may even become knotted near the bend transition between longitudinal portion 51 and transverse portion 53, as will be discussed. Bending of the guide member under tension can increase the friction between the guide member and the lace 23, and severe bending or kinking of the guide member 50 can unduly interfere with the intended operation of the lace system. Accordingly, the attachment mechanism used to attach guide member 50 to the shoe preferably provides sufficient support of the guide member to resist bending and/or kinking. In particular, adequate support is particularly required at the inner radius of any curved portion near the end of the guide member 50.

As shown in fig. 1 and 2, lace 23 also extends around ankle portion 29 past a pair of upper retaining members 44a and 44b located on ankle portion 29. The upper retaining members 44a and 44b are each comprised of a strip of material having a partially raised central portion that defines the space between the retaining member 44 and the upper 24. Upper guide member 52 extends through each of the spaces to guide lace 23 around either side of ankle portion 29 to tightening mechanism 25.

Figure 3 is a schematic perspective view of the lacing system 22 of the boot 20. As shown, each of the side and top guide members 50 and 52 has a tubular configuration with an intermediate cavity 54. The inner diameter of each cavity 54 is greater than the outer diameter of the lace 23 to facilitate sliding of the lace 23 through the side and top guide members 50, 52 and to avoid bending of the lace 23 during tightening and loosening. In one embodiment, the inner diameter of the chamber is about 0.040 inches to cooperate with a lace having an outer diameter of about 0.027 ". However, it should be understood that the diameter of the cavity 54 may vary to suit the appropriate size of a particular lace and other design considerations. The wall thickness and composition of the guides 50, 52 may be varied to take into account the specific requirements set forth by a particular shoe design.

Thus, while the guide 50 is shown as a relatively thin walled tubular structure, any of a variety of guide structures may be utilized, as will be apparent to those skilled in the art in view of the disclosure herein. For example, any of a variety of guide structures may be compressed with a cover 40 that is either permanent (sewn, glued, etc.) or user removable (Velcro, etc.). In one embodiment, the guide 50 is a module having a lumen extending therethrough. Variations on the above are also possible, for example by extending the length of the lace channels in the structure, as shown in fig. 4, so that the overall section has a shallow "U" shaped configuration that allows the retention structure 40 to conveniently retain the overall section. In embodiments of the invention where opposing guides 50 may be sufficiently tied to "bottom out" against opposing, corresponding guides, it may be advantageous to provide a guide member 50 where increased structural integrity may be achieved by a tubule as shown in fig. 2, as will be apparent to those skilled in the art in view of the disclosure herein. The aforementioned strong and relatively stronger lace guides may be utilized throughout the boot, but may be particularly useful in the lower portion of the boot (e.g., the toes).

Generally, each guide member 50 and 52 defines a pair of openings 49 that communicate with opposite ends of the cavity 54. The opening 49 functions as an inlet/outlet for the lace 23. Suitably, the opening is at least as wide as the cross-section of the cavity 54.

As shown in fig. 3, each top guide 52 has a distal end 55, distal ends 55 being spaced from the corresponding side guides 50 on opposite sides of the footwear with the lace 23 extending therebetween. The separation distance will decrease as the lace is tightened. For some products, the wearer may prefer to tighten the toe or foot portions relative to the ankle. This is conveniently accomplished by limiting the ability of the side guides 50 and top guide 52 to move toward each other and beyond a preselected minimum distance during the tying process. For this purpose, it is optional to provide each system with spacers of different lengths. The spacer may snap together at the portion of the strap 23 between the respective end 55 of the top guide 52 and the side guide 50. When the ankle portion of the boot is sufficiently tightened and the wearer still wants to additionally tighten the toe or foot portion of the boot, an appropriate length of spacer can be placed on the lace 23 between the top guide 52 and the side guide 50. Further tightening of the system will therefore not draw the top guide 52 and corresponding side guide 50 closer together.

The stop may be constructed in any of a variety of ways so that it may be removably disposed between the top guide 52 and the side guide 50 to limit relative cinching movement. In one embodiment, the stop includes a sleeve having an axial slot extending through the wall along the length. The sleeve may be placed on the boot by moving the slot forward over the lace 23, as will be apparent to those skilled in the art. Some lengths may be provided, for example, 1/2 inches, 1 inch, 1-1/2 inches, in increments of one-half inch, increasing to three-four inches or more, depending on the location of the reel on the boot and other design features of a particular embodiment of the boot. An increase of 1/4 inches could also be used if desired.

Fig. 30-33 illustrate embodiments of dynamic spacers configured to allow a user to selectively determine the amount of spacing between portions of an article of footwear. The structure shown in fig. 30-33 includes a pair of stops 920 supported by first and second compression bands 902, 904, the first and second compression bands 902, 904 being sandwiched between the bottom cover 906 and the top cover 908. A drive mechanism 910 including a knob 940 may be provided to move the stop 920 laterally.

In use, dynamic spacers, as shown in fig. 30-33, may be provided on the tongue between the covers (or uppers) of the article of footwear. In some embodiments, the dynamic spacer may be disposed between a pair of lace guides. As described above, when the tie 23 is tightened, the lid is pulled together. However, in the dynamic spacer area, the lid edge (or lace guide) will abut the stop 920, thereby preventing further tightening of the footwear area. The dynamic spacer 900 is generally configured to allow a user to adjust the spacing between the stops, and thus the tightness of the dynamic spacer regions. As discussed above, in some embodiments, a wearer may wish to provide greater spacing (i.e., a looser fit) in the toe portion of the article of footwear. Alternatively, in other embodiments, the user may wish to provide greater spacing on the upper of the article of footwear.

The stop 920 is generally supported by the first and second compression bands 902, 904. Referring to fig. 30 and 31, the first and second compression bands 902, 904 each include an elongated slot 922 located near the distal ends 912, 914 of the compression bands 902, 904. Each slot 922 includes a plurality of teeth 924 on one edge, the other edge remaining substantially smooth and free of teeth. As shown in figures 30 and 31, bands 902, 904 are positioned so that slots 922 overlap one another so that teeth 924 of each compression band 902, 904 are positioned on opposite sides of the center line of dynamic spacer 900.

Near their proximal ends 932, 934, the compression bands 902, 904 may further include an attachment hole 936, the attachment hole 936 being configured to secure to the stop 920. In the embodiment shown in FIG. 30, the stop 920 may be fastened to the compression bands 902, 904 by fasteners 926, and the fasteners 926 may extend through the stop 920, the slot in the top cover 908, the fastener holes 936 in the compression bands 902, 904, and the slot in the bottom cover 906. In some embodiments, fasteners 926 may also include a retainer disposed below bottom cover 906 to retain the fasteners within the spacer. The fasteners may be rivets, screws, bolts, pins, or any other suitable means. Similarly, the retaining member may be a crimped rivet head, washer, nut, or any other suitable device.

Fig. 30-62 illustrate an embodiment of a drive mechanism 910 for use with a dynamic spacer 900. The drive mechanism 910 generally includes a knob 940, the knob 940 being configured to rotate in a direction corresponding to the laterally outward movement of the stop 920 (i.e., counterclockwise in the illustrated embodiment). In some embodiments, knob 940 is also configured to lock it or prevent it from rotating in a direction corresponding to the laterally inward movement of stop 920 (i.e., clockwise in the illustrated embodiment). In the illustrated embodiment, the knob 940 includes a plurality of face ratchet teeth 942 on a bottom surface thereof. The top cover 908 can also have a plurality of mating surface ratchet teeth 944, the mating surface ratchet teeth 944 configured to engage the teeth 942 of the knob 940. In the illustrated embodiment, the mating ratchet teeth 942, 944 are generally configured to resist clockwise rotation of the knob 940, thereby preventing the edge of the footwear cover from pushing the stop 920 laterally inward. In alternative embodiments, other unidirectional rotational structures and/or other locking structures may also be utilized. For example, a pin, detent, lever, or other device may be used to prevent rotation of the knob and/or lateral movement of the stop 920. In some embodiments, to allow the stop 920 to move laterally inward, the knob 940 is also configured to be released to allow further cinching in the area of the dynamic spacer 900.

In the illustrated embodiment, the knob 940 also includes a shaft 950 that extends from a bottom surface thereof and includes a drive gear 952, the drive gear 950 configured to engage the teeth 924 of each of the first and second compression bands 902, 904. Gear 952 may be of any suitable type as desired. The number and/or spacing of teeth provided on the gears may vary depending on the degree of mechanical advantage desired. In an alternative embodiment, additional gears may also be provided to provide additional mechanical advantage to the drive mechanism. For example, in some embodiments, a significant mechanical advantage may be beneficial in order to allow a wearer to release a portion of the article of footwear by rotating knob 940 and pushing stop 920 further apart.

In some embodiments, shaft 950 is long enough such that when dynamic spacer 900 is assembled, distal end 954 of shaft 950 extends through central bore 960 of bottom cap 906. After the shaft 950 is inserted through the central aperture 960 of the bottom cap 906, the spring washer 962 may be secured to the distal end 954 of the shaft 950. The spring washer 962 is generally configured to bias the knob 940 downward along the axis of the shaft 950 so that the ratchet teeth 942, 944 remain engaged with one another. In some embodiments, a spring washer 962 can also be configured to allow some degree of upward movement of the knob 940 in order to allow disengagement of the face ratchet teeth 942 and thus lateral inward movement of the dogs 920.

In some embodiments, the top and bottom covers 908, 906 include rails 964, the rails 964 configured to retain and guide the first and second compression bands 902, 904 along a suitable path. The material of the compression bands 902, 904 and the space between the top and bottom covers 908, 906 are typically selected to prevent the compression bands from flexing under the compressive forces that would be exerted by the edges of the footwear cover engaged by the stops 920.

The bottom and/or top covers 906, 908 may be attached to a portion of the article of footwear by any suitable means, such as rivets, adhesives, stitches, hook and loop fasteners, etc., to secure the dynamic spacer 900 to the article of footwear. In addition, in some embodiments, dynamic spacer 900 may be configured to be releasably coupled to portions of an article of footwear. For example, in some embodiments, the tongue of the boot may include multiple attachment locations for the dynamic spacer, such as on the upper, instep portion, toe portion, etc. The dynamic spacer can then be removed from any connection location and moved to another connection location for a different fit. In still other embodiments, the dynamic spacer need not be associated with any portion of the article of footwear. For example, the dynamic spacer may be simply held in place by friction created by the compressive force between the footwear covers.

In alternative embodiments, other drive mechanisms may be provided. For example, a rack and pinion drive gear and teeth may be oriented such that the axis of rotation of the drive gear is perpendicular to the orientation of the illustrated embodiment. In still other embodiments, other mechanical transmission elements, such as a worm, cable/pulley arrangement, or lockable sliding element, may optionally be used to provide adjustable positions between stops 920.

In fig. 3, the top guide 52 is shown not connected to the corresponding side cover 32 for simplicity. However, in actual products, the top guide 52 is preferably fastened to the side cover 32. For example, as noted above, upper retainer 44a is shown in FIG. 2. Alternatively, the top guide 52 may extend within or between layers of material of the side cover 32. As another alternative, or in addition to the above, the end 55 of the top guide 52 may be anchored to the side cover 32 using any of a variety of fastening or clamping arrangements. The lace 23 can be slidably disposed within a sleeve that extends between the spool and the tightening mechanism at the sleeve end 55.

Any of a variety of flexible sleeves may be utilized, such as a spring coil with/without a polymer jacket similar to those currently used on bicycle brakes and push-pull cables. The use of a soft, but axially incompressible, sleeve around the lace 23 between the reel and the tightening mechanism at the end 55 isolates the tightening system from movement of the boot portion, which may include a hinge or flex point, as will be understood in the art. The fastening mechanism may comprise any of a variety of structures including grommets, rivets, staples, sewn or glued eyelets, as will be apparent to those of skill in the art in view of the disclosure herein.

In the illustrated embodiment, each side guide member 50 generally has a U-shape with an opening facing toward the medial line of the footwear. Preferably, each side guide member 50 has a longitudinal portion 51 and two inclined or transverse portions 53 extending from the longitudinal portion 51. The length of longitudinal portion 51 may be varied to adjust the distribution of the closing pressure applied by lace 23 to upper 24 when lace 23 is under tension. Furthermore, on a particular shoe, it is not necessary that the length of the longitudinal portions 51 of all guide members 50 be the same. For example, longitudinal portion 51 may be shortened in the vicinity of ankle portion 29 to increase the closing pressure exerted by lace 23 on the ankle of the wearer. Typically, the length of longitudinal portion 51 ranges from about 1/2 "to about 3", and in some embodiments ranges from about 1/4 "to 4". In snowboard applications, the length of the longitudinal portion 51 is about 2 ". The length of transverse portion 53 typically ranges from about 1/8 "to about 1". In one snowboard embodiment, the lateral portion 52 has a length of about 1/2 ". Various specific length combinations for a specific boot design can be readily optimized by one of ordinary skill in the art through routine experimentation in view of the disclosure herein.

Between the longitudinal portion 51 and the transverse portion 53 is a curved transition portion. Preferably the entire transition portion has substantially the same radius, or is smoothly curved, continuous, without any abrupt edges or changes in radius. This configuration provides a smooth surface over which the lace 23 can slide as it passes around corners. The transverse portion 53 may be eliminated in some embodiments so long as a rounded turn surface is provided to facilitate sliding of the lace 23. In embodiments having a transverse portion 53 and radiused transition portion, with an outer diameter of guide member 50 of 0.090 "and an outer diameter of lace 23 of 0.027", the radius of the transition portion is preferably greater than about 0.1", and typically in the range of about 0.125" to about 0.4 ".

Referring to fig. 3, upper guide member 52 extends substantially around opposite sides of ankle portion 29. Each upper guide member 52 has a proximal end 56 and a distal end 55. Distal end 55 is disposed adjacent the top of tongue 36 for attachment to lace 23 extending from the uppermost side guide member cover 50. The proximal end 56 is coupled to the tightening mechanism 25. In the illustrated embodiment, proximal end 56 includes a rectangular coupling base 57 that engages tightening mechanism 25 to feed the end of lace 23 into tightening mechanism 25, as described more fully below. The guide members 50 and/or 52 are preferably made of a low friction material, such as a lubricious polymer or metal, which facilitates the sliding movement of the lace 23 through the guide members. Alternatively, the guides 50, 52 may be made of any convenient, substantially rigid material, and then provided with a lubricious coating on at least one of the inner faces of the cavity 54 to enhance slidability. The guide members 50 and 52 are preferably substantially rigid to avoid bending and kinking of the lace 23 within the guide members 50, 52 and/or either of the guide members 50 and 52 when tightening the lace 23. The guide members 50, 52 may be made of straight tubes made of a suitably shaped material that is cold-bent or heated and bent.

As an alternative to the tubular guide members described above, guide members 50 and/or 52 comprise open channels, for example, having a semi-circular or "U" shaped cross-section. The channel is preferably positioned on the boot so that the channel opening is not oriented toward the boot midline, and the lace under tension will remain in the channel. One or more retaining strips, stitches or lids may be provided to "close" the open edges of the channel in order to avoid the lace escaping when the tension on the lace is released. Similar to the illustrated tubular embodiment, the axial length of the channel may be performed in a substantially U-shaped configuration, and may be continuous or segmented as described in connection with the tubular embodiment.

Several of the channels may be molded as a single piece, for example, several of the channels may be molded as a common backing support strip that may be glued or sewn to the shoe. Thus, right and left strap retainer strips may be secured to opposing portions of the top and sides of the shoe to provide a set of right guide channels and a set of left guide channels.

Referring to fig. 4, void 206 is elongated such that it defines a lace channel that functions as cavity 54 of lace 23. The chamber 54 preferably includes an elongated region 209, the elongated region 209 extending longitudinally along an edge of the lid 32 or 34 when the guide member 199 is installed on a boot. The elongated region 209 may be straight or may be defined by a smooth curve along its length, such as a continuation of a circle or ellipse. For example, the elongated region 209 may be defined by a portion of an ellipse having a major axis of about 0.5 inches to about 2 inches and a minor axis of about 0.25 inches to 1.5 inches. In one embodiment, the major axis is about 1.4 inches and the minor axis is about 0.5 inches. The chamber 54 further includes lateral regions 210 located at opposite ends of the elongated region 209. The transverse region 210 extends obliquely towards the edges of the lids 32 and 34. Alternatively, the elongated region 209 and the transverse region 210 may merge into one region having a continuous circular or elliptical cross-section to evenly distribute the load along the length of the chamber 54, thereby reducing the overall friction within the system.

Referring to fig. 4, each guide member 199 has a predetermined distance between the first and second openings 207a and 207b of the lace channel in the guide member 199. The effective linear distance between the first and second openings of the lace channel can affect the fit of the boot.

The lace 23 may be formed from any of a number of polymeric or metallic materials, or combinations thereof, that exhibit sufficient axial strength and flexibility suitable for the present application. For example, any of a variety of solid strands, solid polymers, multifilament strands or polymers may be used, which may be braided, knitted, twisted or oriented in different directions. Solid or multi-wire metal cores may be provided with a polymer coating, such as PTFE or other coatings known in the art, in order to reduce friction. In one embodiment, lace 23 comprises twisted cables, such as 7 strand by 7 strand cables made of stainless steel. In order to reduce friction between the lace 23 and the guide members 50, 52 through which the lace 23 slidably passes, it is preferable to coat the outer surface of the lace 23 with a smooth material, such as nylon or teflon. In a preferred embodiment, the diameter of strap 23 ranges from 0.024 inches to 0.060 inches, preferably 0.027 inches. Desirably, the lace 23 is sufficiently strong to withstand a load of at least 40 pounds, and preferably at least 90 pounds. In some embodiments, the lace 23 is rated for at least about 100 pounds up to as high as 200 pounds or more. Lace 23, which is at least five feet in length, fits most footwear sizes, although lesser or greater lengths may be used depending on the design of the lacing system.

The lace 23 may be formed by cutting a cable to a desired length. If lace 23 includes braided or twisted cables, there is a tendency for the strands to separate at the end or tip of lace 23, making it difficult for lace 23 to pass through the openings of guide members 50, 52. As lace 23 is fed through the guide members, the strands of lace 23 easily grip the curved surfaces within the lace guide members. In metal ties, the ends of the strands are often quite sharp, and the use of metal ties also increases the likelihood of the cable catching the guide member as it passes through the guide member. When the tip of each strand grasps the guide member and/or tightening mechanism, the strands separate, making it difficult or impossible for the user to continue threading lace 23 through the small hole in the guide member and/or tightening mechanism. Unfortunately, untwisting the cable is a particular problem with currently available lacing systems in which the user may be required to periodically thread the lace through the lace guide members and into the corresponding tightening mechanism.

One solution to this problem is to provide the tip or end 59 of the lace 23 with a sealed or bonded area 61 in which the strands are held together to avoid separation. The length of the bonded region 61 is shown extended for clarity of illustration. However, the adhesive region 61 may also be a bead located just distal of the most pointed end of the lace 23, and in one embodiment may be an adhesive pointed surface, as long as 0.002 inches, or less.

After the 7 x 7 multi-strand stainless steel cable is tied and untwisted multiple times, the cable tends to become knotted or kinked. The cable may be made from a nickel titanium alloy, such as nitinol, to provide kink resistance to the cable. Other materials may provide the desired resistance to kinking, as will be appreciated by those skilled in the art in view of the disclosure herein. In one particular embodiment, a 1 x 7 multi-strand cable having seven strands of nitinol wire may be constructed, braided together with each strand having a diameter in the range of about 0.005 inches to about 0.015 inches. In one embodiment, a strand has a diameter of about 0.010 inches and a 1 x 7 cable made therefrom has an outer diameter ("OD") of about 0.030 inches. Since nitinol is more flexible, the diameter of the nitinol wire may be larger than the corresponding stainless steel embodiment, and a 1 x 7 configuration, and in some embodiments a 1 x 3 configuration, may be utilized.

In the 1 x 3 configuration, the three strands of nitinol are pulled and then bent to smooth out the appearance, with each strand having a diameter in the range of about 0.007 inches to 0.025 inches, preferably about 0.015 inches. The cross-section of the multi-strand cable being pulled is not circular and the bending and/or pulling causes the cross-section to be approximately circular. Bending and/or pulling also closes the inner space between the strands and improves the crush resistance of the cable. Any of a variety of additives or coatings may be utilized, such as additives that fill interstitial spaces between strands and increase cable smoothness. Additives, such as adhesives, help to hold the strands together and improve the crush resistance of the cable. In other cables, a suitable coating includes PTEF, as will be appreciated by those skilled in the art.

In an alternative construction, the tether or cable comprises a single strand element. In one application, a single strand nitinol wire, such as nitinol, is utilized. Advantages of single strand nitinol wires include the physical properties of nitinol, as well as a smooth outer diameter that reduces friction in the system. Furthermore, the durability of the individual strands can exceed that of the multi-stranded wires, because the individual strands do not crush, and good tensile strength or load carrying capacity can be achieved with small OD individual strands compared to multi-stranded braided cables. Nitinol alloys are very soft compared to other metals and alloys. This is useful because the nitinol lace can follow a fairly tight radius curve through the lace guides and the small spool. If a single strand is used, stainless steel or other materials tend to knot or kink, so these materials are often very useful in twisting cables. However, a disadvantage of twisting the cable is that it squeezes within the spool when the lace is wound on top of it. Furthermore, twisted cables are less robust than monofilament cables at a given diameter due to the space between the strands. The strand bundling arrangement of multi-strand cables and the resulting interstitial spaces are well understood by those skilled in the art. Thus, for a given tensile strength, the volume of a multi-strand cable is greater than the volume of a monofilament cable. The strongest lace of a given diameter is preferred because the spool is preferably the smallest size. In addition, the twined surfaces of the strands create more friction in the lace guides and the spool. The smooth exterior surface of the individual strands creates a low friction environment that further contributes to the cinching, loosening, and load distribution in the dynamic fit of the present invention.

A single strand nitinol wire having a diameter ranging from about 0.020 inch to about 0.040 inch may be utilized depending on the design and desired performance of the boot. In general, too small a diameter may lack sufficient load capacity, and too large a diameter lacks sufficient flexibility to conveniently pass through the system. One skilled in the art, in view of the disclosure herein, can determine the optimal diameter for a given lacing system design through routine experimentation. In many boot embodiments, a single strand nitinol wire having a diameter ranging from about 0.025 inches to about 0.035 inches is desirable. In one embodiment, a single wire having a diameter of about 0.030 inches is utilized.

The ties may be made from wire, cut, or cut to the appropriate length. If sheared, a sharp tip may be produced. It is preferred to remove sharp tips, such as by trimming, grinding and/or solder balls or other methods that produce a sharp point. In one embodiment, the wire is ground and rolled into a conical configuration over a length of about 1/2 inches to 4 inches, and in one embodiment no more than 2 inches. As discussed below, a termination ball or anchor is also preferably provided. Tapering the end of the nitinol wire facilitates the passage of the wire through the lace guide into the spool due to the increased lateral flexibility of the reduced cross-section.

Providing an enlarged cross-sectional area configuration at the end of the wire, such as by soldering, bending, coiling or using a molten or solder ball, is suitable for helping to retain the lace end within the spool and to assist in threading the lace end through the lace guide and into the spool. In one embodiment of the spool discussed elsewhere herein, the compression force of the set screw retains the lace ends within the spool. While the set screw may provide sufficient retention in the multi-strand case, the compressive force of the set screw on the single strand cable does not produce sufficient retention due to the relative crush resistance of the single strand. The use of a solder ball or other enlarged cross-sectional area configuration at the end of the strap can provide an interference fit behind the set screw to help retain the strap within the spool.

In one example, a 0.030 inch diameter single strand lace has a terminal ball with a diameter in the range of about 0.035 inch to about 0.040 inch. In addition, or as an alternative to the termination ball or anchor, slight angles and curves may be provided at the lace tip. This angle may range from about 5 ° to about 25 °, and in one embodiment is 15 °. The angle includes approximately 1/8 inches of the distal end of the tether. This configuration allows the lace to better follow the tight curve and may be combined with a rounded or blunt distal end that facilitates passage and locking in the spool. In one example, a single wire having a diameter of about 0.030 inches has a terminal anchor having a diameter of at least about 0.035 inches. The tether is sanded to a diameter of about 0.020 inches at the point closest to the anchor, and tapers in the proximal direction over a distance of about one inch to just 0.030 inches. Although the term "diameter" is used to describe the terminal anchor, applicant contemplates non-circular anchors such that no true diameter exists. In non-circular cross-section embodiments, the closest approximation of the diameter is utilized for purposes herein.

As an optional end anchor on the lace, a molded piece of plastic or other material may be provided on the end of each strand. In a further variation, each cable end has a removable threading guide. The threading guide may be made of any of a variety of relatively rigid plastics, such as nylon, and may be tapered to easily pass around the corner of the lace guide. After the lace is threaded through the lace guide, the threading guide can be removed from the lace and discarded, and the lace can then be loaded into the reel.

The lace termination anchor can also be configured to mate with any of a variety of connections on the spool. While a setscrew is a convenient means of attachment, the spool has a releasable mechanism to releasably receive the more shaped end of the lace, the lace being abruptly tied and cannot be removed from the spool unless released by a positive action (e.g., release of the lock or lateral movement of the lace in the channel). Any of a variety of releasable interference fits may be utilized between the lace and the spool, as will be apparent to those skilled in the art in view of the disclosure herein.

As shown in FIG. 3, tightening mechanism 25 is mounted to the rear of upper 24 by fasteners 64. While the tightening mechanism 25 is shown mounted to the rear of the boot 20, it should be understood that the tightening mechanism 25 could be disposed in any of a variety of locations on the boot 20. In the case of a skate boot, the cinching mechanism is preferably provided on top of the tongue 36. Alternatively, tightening mechanism 25 may be located at the bottom of the boot heel, the medial or lateral edge of the upper or sole, and anywhere along the medial or lateral line of the shoe. The location of the tightening mechanism 25 can be optimized in view of a variety of considerations, such as the overall design of the boot and the intended use of the boot. The shape and overall volume of the cinching mechanism 25 may vary widely depending on the gear train design, the desired end use, and the location on the boot. A tie-down mechanism 25 of relatively low profile is generally preferred. The profile of the cinch mechanism 25 may be further reduced by recessing the cinch mechanism 25 within the boot wall or tongue. Boots for many purposes have relatively thick walls, for example due to structural support and/or thermal insulation and comfort requirements. In some locations and in some boots, the cinch mechanism may be recessed as much as 3/4 "or more into the boot wall, or in other locations and/or in other boots, similar to 1/8" or 1/2", but without adversely affecting the comfort and function of the boot.

Any of a variety of spool or reel designs may be utilized in the context of the present invention, as will be apparent to those skilled in the art in view of the disclosure herein.

Depending on the gear ratio and the desired performance, one end of the lace can be secured to the guide or other boot portion and the other end wound around the spool. Alternatively, both ends of the lace may be secured to the boot, such as near the toe area, with the intermediate portion of the lace being attached to the spool.

Any of a variety of attachment structures may be utilized to attach the lace ends to the spool. In addition to the illustrated embodiment, the lace can be threaded through the holes and a laterally positioned set screw can be provided so that the set screw can be tightened against the lace, thereby conveniently connecting the lace to the spool. It will be apparent to those skilled in the art that the use of set screws or other releasable clamping structures facilitates removal and reinstallation of the device, as well as replacement of the tie strap.

In any of the embodiments disclosed herein, the lace can be rotatably coupled to the spool at the end of the lace, or at a point on the lace separate from the end. Furthermore, the attachment means is such that the user may or may not remove the lace with or without special tools, or does not desire to be able to remove the lace from the spool. Although the device is disclosed primarily in the context of a design in which the lace ends are connected to the spool, the lace ends may alternatively be connected to other locations on the footwear. In this design, the midpoint of the lace is attached to the spool, such as by adhesive, welding, interference fit, or other attachment technique. In one design, the lace extends through an aperture that extends through a portion of the spool such that the lace wraps around the spool as the spool is rotated. The ends of the lace can be interconnected to form a continuous lace loop.

It is contemplated that the limit of expansion of the boot portion due to the sliding of the lace 23 can be achieved, for example, by one or more straps that extend laterally across the boot 20 at locations where an expansion limit, increased degree of cinching, or support is desired. For example, the strap may extend through the instep portion 30 from one side of the boot 20 to the other side of the boot. A second strap or the only strap may also extend around ankle portion 29.

Referring to FIG. 5, an expansion limiting strap 220 is provided on the ankle portion of boot 20 to supplement the closing force provided by lace 23 and to provide a customizable limit to expansion resulting from the dynamic fit achieved by the lacing system of the present invention. The restraining strap 220 may also prevent or inhibit the wearer's foot from inadvertently backing out of the boot 20 if the strap 20 is untied or disconnected or if the reel fails. In the illustrated embodiment, the strap 220 extends around the ankle of the wearer. The location of the restraining straps 220 may vary depending on the design of the boot and the type of force encountered by the boot during a particular sport.

For example, in the illustrated embodiment, the restraining strap 220 defines an expansion restraining plane that extends generally horizontally and laterally toward the wearer's ankle or lower leg. Thus, although the force is applied by the wearer and another dynamic fit, the inner diameter or cross-section of the footwear cannot exceed a certain value in the expansion limiting plane. The illustrated position tends to limit the dynamic opening at the top of the boot when the wearer bends forward at the ankle. The function of the restraining strap 220 may be accomplished by one or more straps, lines, laces or other structures that wrap around the ankle or are coupled to other components of the boot such that the restraining strap in combination with adjacent boot components provides an extended restraining plane. As shown in FIG. 5, in one embodiment, the expansion limiting band encircles the ankle. The front portion of the strap has an aperture for receiving the reel assembly therethrough. This allows the use of an expansion limiting strap in embodiments with a pre-roll.

In an alternative design, the expansion limiting plane is provided in a substantially vertical direction, for example by providing a limiting strap 220 across the instep in front of the ankle, to achieve different limits on the dynamic fit. In this position, the expansion-limiting band 220 may wrap around the medial or lateral side of the foot of the adjacent footwear component, or may be attached to the sole or other component of the footwear, to provide the same net force effect as if the band wrapped around the foot.

The restraining strap 220 may also create a force restraining plane that is located at an angle between the vertical and horizontal embodiments discussed above, e.g., in one embodiment, the force restraining plane slopes upward from the rear toward the front in a range of about 25 to about 75 from the plane of the sole of the boot. The provision of the restraining strap 220 along an inclined force-limiting plane extending approximately across the ankle advantageously limits upward movement of the foot within the boot, and advantageously controllably limits forward bending of the leg at the ankle relative to the boot.

The strap 220 preferably includes fasteners 222 that can be used to adjust and maintain the tightness of the strap 220. Preferably, the fastener 222 is quickly attachable and releasable so that the restraining strap 220 can be easily adjusted by the wearer. Any of a variety of fasteners can be utilized, such as corresponding hook and loop (e.g., Velcro) surfaces, snaps, clips, cam locks, knotted ties, and the like, as will be apparent to those skilled in the art in view of the disclosure herein.

The strap 220 is particularly useful in current low friction systems. Because the lace 23 tends to slide through the guide members, the tension in the lace can be suddenly released if the lace breaks or the reel fails. This can cause the boot to suddenly open completely, which in turn can cause injury to the wearer, especially if the wearer is performing strenuous activity in the event of a failure. This problem does not exist with conventional lacing systems where the friction in the lace is relatively high, and in addition the tendency of the lace to become caught on conventional eyelets on the footwear precludes the possibility of the lace suddenly becoming completely loosened.

The low friction feature of the present system also provides a dynamic fit around the wearer's foot. During use, the wearer's foot tends to move and change direction constantly, especially during strenuous exercise. This movement causes the tongue and the lid to move with the motion of the foot. The low friction system makes this easier, which easily balances the tension in the straps as the wearer's foot moves. The strap 220 allows the user to adjust the amount of dynamic fit provided by the boot by determining the external limit on expansion that would otherwise occur due to tension balancing, which is automatically accomplished by readjusting the lace throughout the lace guide system.

For example, if the wearer of the boot shown in FIG. 5 does not have an ankle strap 220, as he bends his ankle forward during skating, the increased forward force at the top of the boot causes the tongue to move slightly outward, and the lower lace on the boot tightens. When the wearer again straightens the ankle, the closing force may become equalized and the tongue may remain cinched against the ankle. However, if strap 220 wraps around a wearer's ankle, strap 220 may prevent or reduce forward movement of the ankle and tongue, while reducing the flat boot dynamic fit feature of strap 220 and providing a very different fit and feel to the boot. Thus, the tape provides an effective method of adjusting the amount of dynamic fit that is inherent to low friction dynamic closure systems. Conventional lacing systems do not have as much friction and therefore they do not provide a dynamic fit and thus do not benefit from the webbing in the same way.

Similar straps are often used in conjunction with conventional lacing systems, but for quite different reasons. Similar straps are used to provide the closing force and leverage of the supplemental footwear strap, but are not required for safety, nor to adjust the dynamic fit.

The lacing system 22 described herein advantageously allows the user to further tighten the boot 20 to the foot. Low friction lace 23 incorporates low friction guide members 50, 52 to allow lace 23 to slide easily within guide members 50 and 52. The low friction tongue 36 allows the lids 32 and 34 to be easily opened and closed when the lace is tightened. The lace 23 balances the tension along its length so that the lacing system 23 provides a uniform tightening pressure distribution across the foot. Tightening pressure can be incrementally adjusted by turning a knob on tightening mechanism 25. The user can simply turn or lift or depress a knob or operate any optional release mechanism to automatically release the lace 23 from the tightening mechanism 25 to quickly release the boot 20.

As shown in fig. 6, at least one wear-resistant member 224 is disposed adjacent tongue 36 and between lids 32 and 34. The wear member 224 comprises a smooth disc-shaped structure having a pair of internal channels or cavities 127a, b arranged in a crossed configuration so as to define a crossover point 230. The chambers 127a, b are sized to receive the lace 23 therethrough. The cavities 127a, b are arranged so as to avoid contact of adjacent portions of the lace 23 at the intersection point 230. Thus, wear resistant members 224 avoid chafing of lace 23 at intersection point 230. Wear-resistant member 224 also shields lace 23 from contact with tongue 36 so that lace 23 does not rub or abrade tongue 36.

Optionally, the wear-resistant members 224 may be in the form of a knife edge or point in order to minimize the contact area between the lace 23 and the wear-resistant members 224. For example, at the intersection where the lace 23 intersects the tongue 36, an axially extending (e.g., along the midline of the foot or ankle) ridge or edge may be provided between the tongue 36 and the lace 23. The present wear-resistant member 224 is preferably formed from a mold or from a smooth plastic, such as PTEF, or other material as may be determined by routine experimentation. The lace 23 passes through the tip so that the cross-friction will be limited to a small contact area and smooth surface rather than along the length of the softer tongue material or through the channel or cavity as in the previous embodiments. The tapered edges of wear-resistant members 224 ensure that wear-resistant members 224 maintain reasonable flexibility and help distribute downward loads evenly across the foot. The length along the midline of the foot will vary depending on the design of the boot. This length may be as little as one inch long or less or provided on the tongue where one or more lacing intersections are located, or the length may extend along the entire length of the tongue, with raised ridges or edges of the tongue being more visible in the area where the lacing intersects and less visible where greater flexibility is desired. The wear-resistant member 224 may be integral with or attached to or float on top of the tongue, as with the disks described above.

In one embodiment, the wear-resistant fasteners 224 are fixedly attached to the tongue 36 using any of a variety of well-known fasteners, such as rivets, screws, snaps, stitching, glue, and the like. In another embodiment, wear-resistant fasteners 224 are not attached to tongue 36, but rather float freely on top of tongue 36 and are held in place by engagement with lace 23. Alternatively, wear-resistant member 224 may be integrally formed with tongue 36, such as by threading a first portion of lace 23 through the tongue, with a second, cross portion of lace 23 being above the outer surface of the tongue.

Optionally, one or more portions of the tether 23 extending between the covers 32 and 34 can slidably extend through the tubular protective sleeve. Referring to fig. 6, three intersections are shown, each including first and second intersecting segments of lace 23. At each intersection, a tubular protective sleeve may be provided over each first segment, or over the first and second segments. Alternatively, a short tubular protective outer shell may be provided on one or both of the straps 23 at the intermediate intersection points, which are shown in fig. 6 as supporting the wear resistant members 24. Optimization of the exact number and location of tubular protective segments can be accomplished by conventional methods by those skilled in the art of observing the wear layout of the lacing system in a particular footwear design.

The tubular protective element can comprise any of a variety of tubular structures. Lengths of polymer or metal tubing may be utilized. However, such tubular supports typically have a fixed axial length. Because the distance between the opposing covers 32 and 34 will vary depending on the size of the wearer's foot, the tubular protective wrap should not be too long to inhibit tightening of the lacing system. The tubular protective housing may also have a variable axial length to accommodate tightening and loosening of the lacing system. This may be achieved, for example, by providing a tubular protective housing that includes a slightly stretched coil wall. During the system tie-down, the axial length of the spring guide can be compressed as each of the opposing covers 32 and 34 are drawn toward each other to accommodate different sizes. Another alternative embodiment includes a tubular bellows-like structure having alternating smaller and larger diameter portions, which may also be axially compressed or expanded to accommodate varying foot dimensions. Numerous specific folding structures having pleats or other folds will be apparent to those skilled in the art in view of the disclosure herein. As another alternative, a telescoping tubular sleeve may be utilized. In this embodiment, lace 23 is provided with at least a first tubular sleeve having a first diameter. The lace 23 is also provided with at least a second tubular sleeve having a second, larger diameter. The first tubular sleeve may be slid axially forward within the second tubular sleeve. Two or three or four or more telescopic tubes may be provided to allow the above-mentioned axial adjustability.

Figure 7 schematically illustrates a top view of the insole region of the boot 20. The locking member 232 may be disposed at any one of a number of locations along the lace channel, such as locations "b" and "c," to form a plurality of lace locking regions. By alternately locking and unlocking the locking member 232 and varying the tension in the lace 23, a user can provide areas of varying degrees of tightening along the lace channel.

Figure 8 is a front view of the upper portion of the boot 20. In the embodiment shown in fig. 8, tubular guide members 50 and 52 may be mounted directly within covers 32 and 34, such as within or between single or multiple layers of material. Preferably, the pointed end 150 of each guide member 50 and 52 projects outwardly from the inner edge 152 of each cover 32, 34. As shown in fig. 9, a set of sutures 154 surrounds each guide member 50 and 52. Sutures 154 are preferably disposed directly adjacent guide members 50, 52 so as to form a void 156 therebetween. For ease of illustration, the void 156 is shown having a larger dimension relative to the diameter of the guide members 50, 52. However, the distance between each guide member 50, 52 and the respective suture 154 is preferably small.

Preferably, each set of stitches 154 forms a layout that closely matches the shape of the respective guide member so that the guide members 50, 52 fit closely together within the covers 32, 34. Thus, the stitches 154 inhibit deformation of the guide members 50, 52, particularly the inner radii of the guide members 50, 52, when the lace is cinched. Advantageously, the suture 154 also functions as an anchor that prevents the guide members 50, 52 from moving or shifting relative to the covers 32, 34 during tightening of the lace.

The void 156 may be partially or completely filled with a material, such as glue, configured to stabilize the position of the guide member 50, 52 relative to the cover 32, 34. The material is selected to further inhibit movement of the guide members 50, 52 within the gap 156. The directing member may also be provided with anchoring means, such as differently shaped tabs, which are arranged at different positions of the directing member, the tabs being configured such that they further inhibit movement or deformation of the directing members 50, 52 relative to the lid 32. The anchoring member may also include notches or grooves on the guide members 50, 52 that create friction when the guide members 50, 52 begin to move, thereby inhibiting further movement of the guide members 50, 52. The grooves can be formed by different methods, such as sanding, sandblasting, etching, etc. Axial movement of the guide tube 50 or 52 may also be limited by using any of a variety of guide tube stops (not shown). The guide tube stop includes a tubular body having an opening that provides access to a lumen extending therethrough. The stop may also be provided with one or more fastening tabs for sewing or gluing to the shoe, as discussed above. Once sewn or otherwise secured, the tab blocks axial movement of the device along its longitudinal passageway.

Referring to fig. 10 and 11, optional guide member 250 comprises a thin, single-piece structure having an interior cavity 252 for passage of lace 23 therethrough. The guide member 250 includes a body portion 254 that defines a substantially straight guide member inner edge 256. The flange portion 260 extends peripherally around one edge of the body portion 254. The flange portion 260 includes a region of reduced thickness relative to the body portion 254. An elongated slot 265 including a second region of reduced thickness is provided in the upper surface 266a of the guide member 250.

A pair of lace exit holes 262 extend through the sides of the lace guide 250 and communicate with the cavity 252. Lace exit hole 262 can be oval-shaped to allow lace 23 to exit therethrough at a variety of exit angles.

Referring to fig. 10 and 11, a series of lower and upper channels 264a, 264b extend through upper and lower surfaces 266a, 266b, respectively, of lace guide member 250. The channel 264 is disposed so as to extend along the passageway of the cavity 252 and communicate therewith. The position of each upper channel 264a is preferably continuously staggered along the path of the chamber from the position of each lower channel 264b, thereby offsetting upper channels 264a relative to lower channels 264 b.

Referring to fig. 12 and 13, the flange region 260 is inserted directly into the cover 32, 34 to mount the lace guide member 250 on the cover 32, 34, such as within or between single or multiple layers 255 (fig. 13) of material. The layer 255 may be filled with a filler material 257 to maintain the thickness of the covers 32, 34 constant.

The lace guide members 250 can be fastened to the covers 32, 34, such as by stitching through the covers 32, 34 and the lace guide members 250 to form a stitched arrangement 251. The thread is preferably stitched through the reduced thickness region of the flange portion 260 and the elongated slot 265. Preferably, the covers 32 and 34 are cut so that the main body portion 254 of the guide member 250 is exposed on the covers 32, 34 when the lace guide member 250 is disposed on the covers 32, 34.

Referring to fig. 13, the upper surface 266a of the body portion of the guide member 250 is preferably flush with the upper surface of the covers 32, 34 to maintain a smooth, continuous appearance and clear discontinuities in the covers 32, 34. Advantageously, because the thickness of the flange region 260 is reduced, the lace guide members 250 are configured to provide a small increase in thickness to the covers 32, 34, preferably no increase in thickness of the covers. Thus, when the guide member 250 is installed in the covers 32, 34, the lace guide member 250 does not create any lumps.

As mentioned, a series of upper and lower offset channels 264a, b extend through the lace guide 250 and communicate with the cavity 252. The offset placement of the channels advantageously facilitates manufacturing the guide member 250 as a unitary structure, such as by using a closure during an injection molding process.

The shape of the cavity may be approximately defined by an ellipse. In one embodiment, the ellipse has a major axis of about 0.970 inches and a minor axis of about 0.351 inches.

Fig. 14 is a side view of an alternative tie-down mechanism 270. The tightening mechanism 270 includes a housing 272 having a control mechanism, such as a rotatable knob 274, mechanically coupled to the housing 272. The rotatable knob 274 is slidable along an axis a between two positions relative to the housing 272. In the first position, the engaged position, the knob 274 is mechanically engaged with an internal gear mechanism located inside the housing 272. In the second position, i.e. disengaged position (shown in dashed lines), the knob is arranged upwards with respect to the first position and is mechanically disengaged from the gear mechanism. The tightening mechanism 270 can be removably mounted to the front, rear, top or sides of the boot.

The closure system includes a rotatable spool for receiving the lace. The spool may be rotated in a first direction to retract the lace and in a second direction to release the lace. The knob is connected to the spool such that rotation of the knob rotates the spool in a first direction only to retract the lace. A releasable lock is provided to prevent rotation of the spool in the second direction. The convenient locking mechanism is released by pulling the knob axially away from the boot, thereby enabling the spool to be rotated in a second direction to unwind the lace. However, the spool only rotates in the second direction with lace traction. The spool cannot rotate in the second direction with rotation of the knob. This avoids tangling of the lace in or around the spool, which can occur if reverse rotation of the knob can loosen the lace without commensurate lace traction.

In the above embodiments, the wearer must pull sufficient length of cable from the spool to enable the wearer's foot to enter or exit the footwear. The resulting slack cable requires multiple turns of the winding spool to begin tightening the boot. An optional feature according to the invention is to provide a spring drive or bias within the spool that automatically winds the slack cable, similar to the mechanism in the self-biasing auto-winding tape approach. The spring bias in the spool is typically not strong enough to tie the boot, but is sufficient to wind up the slack cable. The wearer then engages the knob and manually tightens the system to the desired tightening state.

Self-winding springs may also be used to limit the amount of cable that can be accepted by the spool. This is accomplished by calibrating the length of the spring so that after the knob is engaged and the boot is tightened, the knob can only be rotated a predetermined number of additional turns, the spring then bottoms out, and the knob cannot be rotated. This limits how much of the lace cable can be wound onto the spool. Without such a limitation, if the cable used is too long, the wearer may inadvertently wind up the lace cable until the lace cable is tightly caught on the outer shell of the spool and cannot be pulled back outward.

Fig. 21-27 illustrate one embodiment of a lace spool 600 that includes a spring configured to automatically clear slack in the lace 23 by maintaining the lace 23 under tension. In the illustrated embodiment, the spool 610 generally included with the roll 600 is disposed within the housing member 620 and rotationally offset in the winding direction. The spool 610 is also typically coupled with a knob 622 for manually tightening the lace 23. Many of the features of the roll 600 shown in fig. 21-27 are substantially similar to the tightening mechanism 270 discussed above with reference to fig. 14. However, in alternative embodiments, the spring biased spool 600 may be applied to many other tie-down mechanisms as desired.

Figure 21 illustrates an exploded view of one embodiment of a strap reel 600. The embodiment shown in fig. 21 shows a spring assembly 630, a spool assembly 632, and a knob assembly 634. The spool assembly 632 and spring assembly 630 are generally configured to be assembled together and disposed within the housing 640. The knob assembly 634 may then be assembled with the housing 640 to provide the self-winding lace arrangement 600.

The knob assembly 634 generally includes a knob 622 and a drive gear 642, the knob 622 and the drive gear 642 configured to rotatably couple the knob 622 with a drive shaft 644, the drive shaft 644 extending substantially through the entire spool 600. In alternative embodiments, the knob assembly 634 may include any of the other devices described above, or any other unidirectional rotation device.

Referring to fig. 23-26, in some embodiments, the housing 640 generally includes an upper portion having a plurality of ratchet teeth 646, the ratchet teeth 646 configured to engage a pawl 648 with the knob 622 (see fig. 22). The housing 640 further includes a spool cavity 650, the spool cavity 650 sized and configured to receive the spool assembly 632 and the spring assembly 630 therein. The lower portion of the spool cavity 650 includes a plurality of teeth forming a ring gear 652, the ring gear 652 being configured to mesh with planet gears 654 of the spool assembly 632.

A transverse surface 656 generally separates the upper portion of the housing 640 from the spool cavity 650. A central aperture 658 in the transverse surface allows the drive shaft 644 to extend from the knob 622 through the housing 640 and the spool assembly 632. In some embodiments, set screw holes 660 and/or winding pin holes 662 may also extend through the housing 640, as will be described further below. The housing 640 also generally includes a pair of lace access holes 664 through which lace can extend.

As discussed above, a gear train may be provided between the knob 622 and the spool 610 to allow a user to apply a torsional force to the spool 610 that is greater than the force applied to the knob. In the embodiment shown in fig. 21-25, this gear train can be provided in the form of a planetary gear set including a sun gear 670 connected to the spool 610 and a plurality of planet gears 654 and a ring gear located on the inner surface of the housing 640. The planetary gear train causes the drive shaft 644 to rotate clockwise relative to the housing 640, resulting in the spool 610 rotating clockwise relative to the housing 640, but at a much slower speed and with a greatly increased torque. This provides the user with a major mechanical advantage in tightening the footwear lace using the device shown. In the illustrated embodiment, the planetary gear train provides a gear ratio of 1: 4. In alternative embodiments, other gear ratios may be used as desired. For example, any gear ratio between 1:1 and 1:5 or more may be used in conjunction with the footwear lace tightening mechanism.

With reference to fig. 21, 23 and 25, an embodiment of the spool assembly 632 will now be described. The spool assembly 632 generally includes a spool body 610, a drive shaft 644, a sun gear 670, a plurality of planet gears 654, a pair of set screws 672, and a bushing 674. The spool body 610 generally includes a central bore 676, a pair of set screw holes 678, a winding portion 680, and a transmission portion 682. The winding portion 680 includes a pair of holes 684 to receive a lace end that can be secured to the spool using set screws 672 or otherwise, as described in the above embodiments. Hole 684 is generally configured to receive a strap and is aligned with the strap entry hole in housing 640. In some embodiments, the spool 610 further includes a winding peg hole 690, the winding peg hole 690 configured to receive a winding peg for assembling the spool 600, as will be described further below. In some embodiments, the spool 610 may also include a viewing hole 692 to allow a user to visually verify that the lace 23 has been inserted a sufficient distance into the spool 610 without the need to mark on the lace 23.

Bushing 674 includes an outer diameter that is slightly larger than the inner diameter of hole 676 in the spool. The bushing 674 also includes an internal bore 694 that is configured to engage the drive shaft 644 such that the bushing 674 remains rotationally stationary relative to the drive shaft throughout device operation. In the illustrated embodiment, the drive shaft 644 includes a hexagonal shape and the bushing 674 includes a corresponding hexagonal shape. In the illustrated embodiment, sun gear 670 also includes a hexagonal aperture 702, with hexagonal aperture 702 configured to couple sun gear 670 with drive shaft 644. Alternatively or additionally, the sun gear 670 and/or the bushing 674 may be secured to the drive shaft 644 by a press fit, a bolt, a set screw, an adhesive, or other suitable means. In other embodiments, the drive shaft 644, bushing 674, and/or sun gear 670 may include other cross-sectional shapes to rotationally couple elements.

In the assembled condition, the bushing 674 is disposed within the spool bore 676, and the drive shaft 644 extends through the central bore 694 of the bushing 674 and the sun gear 670. In some embodiments, the planet gears 654 may be secured to the axle 704, with the axle 704 being fixedly secured to the drive section 682 of the spool 610. When assembled on the spool 610, the planet gears 654 extend generally radially outward from the periphery of the spool 610 so as to be engageable with the ring gear 652 within the housing 640. In some embodiments, the spool transmission portion 682 includes a wall 706 provided with an aperture to allow the planetary gears 654 to extend therethrough. If desired, a plate 710 may be provided between the planet gears 654 and the spring assemblies 630 to avoid interference between the moving parts.

The spring assembly 630 generally includes a coil spring 712, a spring punch 714 and a support plate 716. In some embodiments, a washer/plate 718 may also be provided within the spring assembly 630 between the coil spring 718 and the spring punch 714 to prevent the spring 712 from undesirably catching any protruding portions of the spring punch 714.

Referring specifically to fig. 27, in some embodiments, the spring boss 714 can be fixedly attached to the support plate 716, and the torsion spring 712 can be configured to engage the spring boss 714 in at least one rotational direction. The coil spring 712 generally includes an outer end 720 disposed at the periphery of the spring 712 and an inner end 722 located in the middle of the spring 712. The outer end 720 is generally configured to engage a portion of the spool 510. In the illustrated embodiment, the outer end 720 includes a constricted portion for engaging a hole in a portion of the spool 610. In alternative embodiments, the outer end 720 of the spring 712 may be secured to the spool by a weld, mechanical fastener, adhesive, or any other suitable method. The inner end 722 of the spring 712 includes a hook portion configured to engage the spring boss 714.

The spring punch 714 includes a pair of posts 730 extending upwardly from the support plate 716. Post 730 is generally crescent-shaped, and post 730 is configured to engage the hooked inner end 722 of spring 712 in only one rotational direction. Each post 730 includes a curved portion 736, the curved portion 736 configured to receive the hooked spring end 722 when the spring is rotated counterclockwise relative to the support plate 716. Each post 730 also includes a flat end 738, the flat end 738 being configured to deflect the hooked spring end 722 when the spring 712 is rotated clockwise relative to the support plate 716. In the illustrated embodiment, the post 714 and spring 712 are positioned such that clockwise rotation of the spring 712 relative to the spring punch 714 and support plate 716 will allow the spring to "jump" from one post 714 to another without impeding such rotation. On the other hand, counterclockwise rotation of spring 712 causes hooked end 722 to engage one of posts 714, thereby holding spring inner end 722 stationary relative to the exterior of spring 712. Continued rotation of the spring exterior deflects the spring, thereby biasing the spring in the clockwise winding direction.

The space 732 between the posts 730 of the spring punch 714 is generally sized and configured to receive the distal end of the drive shaft, which in some embodiments, as shown in fig. 21, may include a rounded end 734 configured to freely rotate within the spring punch space 732. In the embodiment shown in fig. 21, the spring punch 714 and the support plate 716 are shown as separately manufactured, post-assembled elements. In alternative embodiments, the support plate 716 and the spring punch 714 may be integrally formed as part of a unitary structure and/or another structure.

An embodiment of a method of assembling the self-winding lace spool 600 will now be described with reference to fig. 21-26. In one embodiment, the sun and planet gears 670, 654 are mounted on a transmission portion 682 of the spool 610, and the bushing 674 and drive shaft 644 are inserted through a hole 676 in the spool. The spring assembly 630 is assembled by attaching the spring punch 714 to the support plate 716 by any suitable method and disposing the spring 712 on the spring punch 714. The spool assembly 632 may then be coupled to the spring assembly 630 by coupling the outer end 720 of the spring 712 to the spool 610. In some embodiments, the spring may need to be pre-wound to fit within the spool wall 706. The spool assembly 632 and spring assembly 630 may then be disposed within the housing member 640. In some embodiments, the support plate 716 is fastened to the housing member 640 by screws 740 or any other suitable fastener, such as rivets, welds, adhesives, and the like. In some embodiments, the support plate 716 includes a notch 742, the notch 742 configured to cooperate with an extension or recess in the housing member 640 to prevent full torsion spring loading against the screw 740.

In some embodiments, once the spool assembly 632 and spring assembly 630 are assembled and disposed within the housing 640, the spring 712 may be tensioned prior to tying the lace. In one embodiment, referring to fig. 26, the spring 712 is tensioned by holding the housing 640 stationary and rotating the drive shaft 644 in the unwind direction 740, thereby increasing the deflection of the spring 712 and correspondingly increasing the biasing force of the spring. Once the desired degree of deflection/spring bias is achieved, the winding pin may be inserted through the winding pin hole 662 in the housing 640 and the winding pin hole 690 in the spool 610.

In one embodiment, the winding pin holes 690 in the spool are aligned with respect to the winding pin holes 662 in the housing such that when the winding pins 742 (see also fig. 25) are inserted, the positioning screw holes 678 and the lace viewing holes 692 in the spool 610 align with the corresponding holes 660 in the housing 640. It is also preferred that the arrangement 610 and the housing 640 be such that when the winding peg bore 690 is aligned with the bore 662, the lace receiving bore 684 of the spool 610 is aligned with the lace entry bore 664 of the housing 640. In alternative embodiments, winding pin holes 690 and holes 662 may be omitted and the spool may be positioned in place relative to the housing by other methods, such as may be inserted through set screw holes and holes or viewing holes/bores to position winding pins 742.

Once the spring 712 is tensioned and the winding pin 742 is inserted, the lace 23 can be installed in the spool using any suitable method provided. In the embodiment shown in fig. 21-26, the spool 610 is configured to secure the lace 23 therein with a set screw 672. Lace can be inserted through the lace entry hole 664 in the housing 640 and the lace receiving hole 684 in the spool 610 until the user sees the end of the lace at the appropriate viewing hole 692. Once the user visually verifies that the lace has been inserted a sufficient distance, the set screw 672 may be tightened to secure the lace within the spool.

Once the strap 23 is tightened, the winding pin 742 can be removed, allowing the spring to wind up any slack in the strap. Knob 622 may then be attached to housing 640, for example, by tightening screw 750 on drive shaft 644. The user may then tighten the lace 23 using the knob 622 as desired.

In an alternative embodiment, it may be desirable to pre-tension the spring 712 after the lace 23 is installed in the spool 610. For example, if the end user wishes to change the lace in his/her footwear, the old lace 23 can be removed by removing knob 622, loosening set screw 672, and pulling lace 23 out. A new lace can then be inserted through the lace access hole 684 and secured to the spool using the set screw 672 and the knob 622 reinstalled as described above. Then, to tighten the spring 712, the user can simply rotate the rotation knob 622 in the winding direction until the lace is fully tightened (the foot is not typically in the footwear). The spring does not resist this forward winding because the spring punch 714 would allow the spring 712 to rotate freely in the forward direction described above. In a preferred embodiment, the user tightens the lace as much as possible when the foot is not in the footwear. Once the lace is fully tightened, the knob may be released and the lace may also be pulled out, for example by pulling the knob outward as described above. As the spool rotates in the unwinding direction, the hooked inner end 722 of the spring 712 engages the spring punch 714 and the spring deflects, again biasing the spool 610 in the winding direction.

In an alternative embodiment, the lace reel is particularly useful for running shoes that do not require the lace to be very tight. Some current running shoes employ elastic laces, however, these systems are difficult, if not impossible, to lock once the desired lace tension is achieved. Thus, embodiments of a lightweight spring biased self-winding lacing arrangement can be provided by eliminating the knob assembly 634, gears 654, 670, and other components associated with a manual tightening mechanism. In this embodiment, the spool 610 can be greatly simplified by eliminating the transmission section 682, and can also significantly reduce the complexity of the housing 640 by significantly reducing the size of the ring gear section 652 and the ratchet teeth 646. The simplified spool can then be directly connected to the spring assembly 630, which can provide a simple locking mechanism to prevent the lace from unwinding during walking or running.

Thus, the right and left spools may be configured to rotate in opposite directions, allowing the user to more naturally grasp and manipulate the spools. It is presently believed that the motion of lifting the hand over the shoulder, for example, as the person's right hand rotates clockwise, is a more natural motion and may provide more torque to tighten the reel. Thus, by configuring the right and left spools for rotation in opposite directions, each spool is configured to be tightened with the right hand and the left hand, thereby tightening each spool in a shoulder-by-shoulder motion.

Alternatively, guide member 490 may include a lace guide defining an open channel, e.g., a semi-circular, "C" -shaped, or "U" -shaped cross-section. The guide member 490 is preferably positioned on the boot or shoe so that the channel opening is not oriented toward the midline of the boot so that a lace under tension will be retained therein. One or more retaining strips, sutures or covers may be provided to "close" the channel openings to prevent the laces from escaping when tension on the laces is released. The axial length of the channel may be performed substantially in a U-shaped configuration. Moreover, any axial configuration of the guide member 490 is possible in practice and is determined primarily by the style and only partially by the function.

Several guide members 490 may be molded as a single piece, for example several lace guides 491 are molded as a common backing support strip that may be glued or sewn to the shoe. Thus, the right and left lace guide members can be fastened to opposing portions of the top or sides of the footwear to provide a set of right guide channels 492 and a set of left guide channels 492. When referring to "right" and "left" guide members, it should not be understood to imply a fixed position of the fastener strip. For example, guide member 490 may be positioned on a single side of a footwear, such as a footwear upper where the upper extends generally from one side of the footwear, across the midline of the foot, and fastened to the opposite side of the footwear by a strap. In this type of shoe, the guide members 490 are actually arranged perpendicularly with respect to each other, and therefore, the left and right guide members merely refer to the fact that the openings of the guide members 490 face each other, as shown in fig. 16.

Fig. 15 and 16 illustrate an assembled configuration of an example embodiment and the present footwear lacing system. For example, a plurality of guide members 490 may be provided in place of a conventional footwear eyelet line, as described above. Typically, the guide members 490 are mounted as opposed pairs of guide members, the guide members being integrally formed with the spool 498 as one, the spool 498 typically including one of the guide members. The term "spool" will be used hereinafter to refer to the various embodiments of the complete structure including the housing and its internal components, unless otherwise specified. Thus, in some embodiments, two, four, six, or eight or more cooperating guide members 490 are installed to define the lace channels. In addition, an unpaired guide member 490 may be installed, for example toward the toe of the shoe, disposed transverse to the midline, and having a lace opening toward the heel of the shoe. This configuration, in addition to applying a lacing force between the lateral and medial sides of the footwear, also applies a lacing tension along the medial line of the footwear. Of course, other numbers and arrangements of guide members may be provided, and the application and claims should not be limited to configurations utilizing opposing or even pairs of guide members.

In the embodiment shown in fig. 15, the reel 498 is provided on the lateral rear side panels of the shoe. Of course, the roller 498 may be disposed in virtually any location on the footwear, and only some preferred locations are described herein. Further, the illustrated reel may be any reel embodiment suitable for practicing the present invention and should not be limited to a particular embodiment. The illustrated embodiment provides three separate guide members 490 along the void between the footwear medial quarter panel 500 and lateral quarter panel 502 to form a lacing channel that zigzags through the tongue 504. Although the reel 498 is shown disposed on the side quarter panels 502 near the ankles, the reel 498 may also be disposed on the middle quarter panel 500 of the shoe. In some embodiments, the roller 498 is disposed on the same rear side enclosure of each shoe, for example, the roller may be disposed on the side rear side enclosure 502 of each shoe, or in alternative embodiments, the roller may be disposed on the side rear side enclosure 502 of one shoe, on the middle rear side enclosure 500 of the other shoe.

Notably, this embodiment has lace channels that form an acute angle α as they enter the shell. As discussed above, the lace guide members may be integrally formed with the housing to substantially diametrically guide the lace proximate to and interacting with the spool. Thus, the sum of the tension applied to the reel is substantially cancelled.

Figure 17 illustrates an alternative embodiment of a footwear including an upper closure structure. In this particular embodiment, the reel 498 may be disposed on the upper 506, or may be disposed on the lateral rear side panels, or even within the heel, as disclosed above. Similar to fig. 15, the spool shown in fig. 16 should not be limited to one particular embodiment, but rather should be understood to be any suitable embodiment of a spool for use with the present invention. In the illustrated embodiment, three lace guides 490 are attached to the shoe; two on the side quarter panels 502 and one on the vamp 506 which cooperates with the guide members integrally formed with the roller 498 to define the lace channels between the side quarter panels 502 and the vamp 506. One of ordinary skill in the art will recognize that the guide members may be appropriately spaced to create different tie-down methods.

For example, opposing guide members 490 may be spaced further apart to allow for a greater range of tightening. More specifically, by further separating the opposing guide members 490, a greater distance may be used to effect cinching before the guide members 490 bottom out. This embodiment provides the additional advantage of extending lace 23 over a substantially flat portion of the footwear, rather than extending through a portion of the footwear having a convex curvature.

Figure 17 shows an alternative arrangement for a shoe, which includes a closed upper structure and has a roller and a strap that does not form a loop. In this embodiment, the open-ended strap may be attached directly to a portion of the footwear. As shown, the roller 498 is disposed on the side rear side gusset 502 of the shoe. The shoe has one or more lace guides 490 strategically placed on the shoe. As shown, one lace guide 490 is disposed on the upper 506 and a second lace guide 498 is disposed on the side quarter panel 502. One end of the lace is attached to a spool within the spool 498 and the lace extends from the spool 498 through the lace guide 490 and is directly attached to the shoe via any suitable connection 512. In those embodiments where the reel 498 is provided on the side quarter panel 502, one suitable location for attaching the lace is on the toe-facing upper.

The connection 512 may be a permanent connection or may be releasable to allow removal and replacement of the strap as desired. The connection is preferably a suitable releasable mechanical connection, for example a clip, clamp or screw. Other types of mechanical, adhesive, or chemical bonding may also be used to attach the strap ends to the footwear.

While the illustrated embodiment shows the roller 498 coupled to the side quarter panel 502, it will be apparent that the roller 498 can be readily coupled to the upper 506 and provide the advantageous features disclosed herein. In addition, the strap may optionally be attached to the shoe on the side quarter panel 502 instead of on the upper 506. The reel 498 and the strap may be attached to the same portion of the footwear as shown, or may be attached to different portions of the footwear. In any event, as the lace is tightened around the spool, the lace tension draws the guide members toward one another and tightens the footwear over the wearer's foot.

The shoe is typically curved across the midline to accommodate the dorsal anatomy of a human foot. Thus, in embodiments where the lace traverses the medial line of the shoe in a zigzag pattern, the farther apart the lace guides 490 are, the closer the lace 23 is to the sole 510. As a result, with lace 23 cinched, the line between lace guides 490 is blocked by the footwear midline, which can place significant stress on the tongue, further discomfort to the wearer, and increased friction and wear on the tongue. Thus, by placing strap 23 across a substantially smooth surface of a lateral or medial portion of the footwear, strap 23 may be further tightened without applying pressure to other portions of the footwear.

It is contemplated that some embodiments of lacing system 22 discussed herein will be included in athletic footwear and other athletic equipment that are susceptible to impact. Examples include, among others, cycling shoes, ski boots and snowboard boots, and protective sports equipment. Accordingly, the spool is preferably protected from inadvertent release of the spool and lace by impact with external objects.

The lacing system 22 shown in fig. 18 and 19 further has a protective element to protect the spool from impact by external objects. In one embodiment, the protective element is a shield 514 that includes one or more raised ridges 516 or ramps, the raised ridges 516 or ramps configured to extend away from the mounting flange 406 a distance high enough to protect the spool that would otherwise be exposed. In the illustrated embodiment, the guard 514 is configured to be angled toward the spool to provide an angled surface for any object that the spool may contact to deflect the object away from the spool. The shield 514 is circumferentially disposed about the spool and is radially inclined toward the spool and may encircle the spool or may be disposed about one-half spool, one-quarter spool or any suitable portion of the spool.

The guard 514 may be formed integrally with the mounting flange 406, such as during a molding process, or may be formed as a single piece and then connected to the lacing system 22, such as by an adhesive or other suitable bonding technique. Preferably, the shield 514 is formed of a material having sufficient hardness to withstand repeated impacts without plastically deforming or exhibiting undue signs of wear.

Another embodiment of the protective element is shown in fig. 20. In this embodiment, the shield 514 is in the form of a raised lip 517 that surrounds a circumferential portion of the knob (not shown). The lip 517 may be of sufficient height to extend beyond the top of the knob, or may extend below the knob height so that a user can still grasp the knob above the lip 517, or the lip 517 may be formed at a different height. The lip 517 is preferably designed to withstand impacts from different objects, thereby protecting the knob from inadvertent rotation and/or axial movement.

The lip 517 may be integrally molded with the mounting flange or may be a single piece. Furthermore, the lips 517 may have different shapes and sizes in order to satisfy aesthetic taste while providing protective function according to the purpose designed. For example, lip 517 can be formed with different draft, height, and bottom flat edge, as well as from different materials, and the like. In the illustrated embodiment, the lip 517 extends substantially around the entire circumference of the knob 498, except at the support 521, where the lip 517 recedes sufficiently to allow a user to grasp a substantial portion of the height of the knob, thereby enabling the knob to be moved axially by lifting the knob away from the housing. The shown embodiment additionally shows that the lips 517 extend outwards in order to protect a significant part of the knob height. While the lip 517 is shown as extending around a certain portion of the circumference of the knob, it may of course extend more or less around the circumference of the knob. Some preferred embodiments include a continuous shield 514 extending around one-quarter of the knob circumference and one-half of the knob circumference, while other embodiments include a shield 514 that includes one or more discrete portions that, in combination, cover any suitable range around the knob circumference. Of course, other protective elements or shields 514 for protecting the spool may be included, such as a protective cover or lid covering the spool, a cage structure over the spool, and the like.

Fig. 28-30D illustrate embodiments of alternative lacing arrangements that are generally configured to provide multiple lacing zones for an article of footwear. This multi-zone lacing system provides a great benefit by a user independently tightening different portions of an article of footwear to different tightening states. For example, in many instances it may be desirable to tie the toe portion tighter than the upper. In other situations, the user may desire the opposite, i.e., tight upper, and loose toe portion. In either case, however, a user typically desires heel compression at the ankle portion of the footwear. Thus, in addition to providing multiple independent lacing regions, the system shown in fig. 28-30D is advantageously arranged to cinch the ankle portion of the article of footwear under the tension of the tighter of the two laces.

Fig. 28 is a schematic illustration of one embodiment of a multi-zone lacing system 800. The system shown in fig. 28 includes a first lace tightening mechanism 802 and a second lace tightening mechanism 804, with the first lace tightening mechanism 802 and the second lace tightening mechanism 804 configured to tighten the first lace 23a and the second lace 23 b. In some embodiments, first tightening mechanism 802 may be provided on the tongue, while second tightening mechanism 804 may be provided on the side of the boot. Alternatively, both fastening mechanisms 802, 804 may be provided on the tongue or on the sides of the footwear. In alternative embodiments, the mechanism may be disposed on the article of footwear in different ways. In further alternative embodiments, a multi-zone lacing system may have a single lacing system that includes multiple independently operable spools. These individually operable spools can be operated by a single knob and selector mechanism, or each spool can include its own knob.

One embodiment of the multi-zone lacing system 800 is preferably a dual loop lacing system, wherein the first lacing loop has a first lace 23a having a first length and the second lacing loop has a second lace 23b having a second length. In some embodiments, first strap 23a and second strap 23b have the same length. In other embodiments, the length of second strap 23b preferably ranges from about 100% to about 150% of the length of first strap 23 a. In some embodiments, the length of second strap 23b is preferably at least 110% of the length of first strap 23 a. In further embodiments, the length of second strap 23b is preferably at least 125% of the length of 23 a. In alternative embodiments, the lengths of first strap 23a and second strap 23b may be reversed. The first loop has a lock 802, such as a roller disposed on the tongue of the footwear, and the second loop has a lock 804, such as a roller disposed on the side or rear of the footwear. Alternatively, locks 802, 804 may be provided elsewhere on the footwear, including both on the tongue or both on the sides or rear of the footwear.

The multi-zone lacing system 800 schematically illustrated in fig. 28 is a three-zone lacing system. Each zone is generally defined by a pair of transverse lace guides that are drawn toward one another generally along a line between their centers. Thus, the first lace region 810 is defined by the first lace 23a extending between the first lace guide 812 and the second lace guide 814, the second lace region 820 is defined by the second lace 23b extending between the third lace guide 822 and the fourth lace guide 824, the third lace region 830 is defined by the region between the fifth lace guide 832 and the sixth lace guide 834, and both the first lace 23a and the second lace 23b extend through the fifth lace guide 832 and the sixth lace guide 834. In alternative embodiments, a multi-zone lacing system may have only two zones, or four or more zones, each of which may include any number of overlapping laces, as desired.

In the embodiment of FIG. 28, the overlapping lace third lace region 830 provides the unique advantage of automatically tightening the third region 830 according to the tighter of the two laces 23a, 23 b. In one embodiment, third lace region 830 is co-located with an ankle portion of the article of footwear. In this embodiment, the third lacing region is advantageously located along the ankle plane, which can extend through the pivot axis of the wearer's ankle at any angle between zero and 90 degrees relative to horizontal. In some embodiments, the third region lock lies in a plane between about 30 degrees and about 75 degrees relative to horizontal. In one embodiment, the ankle plane is positioned above the horizontal plane at a 45 angle. In an alternative embodiment, the third lacing region 830 is located along a plane that passes through the pivot axis of the last heel and ankle of the wearer. By providing the third lacing region along the ankle plane, the wearer's ankle may be tightly secured within the footwear regardless of which lace is tighter.

As shown in fig. 28, multi-zone lacing system 800 employs multiple lace guides of varying types. For example, the upper portion of the first lace 23a and the lower portion of the second lace 23b are shown extending through first, second, third, and fourth curved lace guides 812, 814, 822, and 824, respectively. Each of the curved lace guides 812, 814, 822, 824 includes a guide portion 842 for substantially frictionless engagement with the lace 23 and the connecting portion 844 to secure the lace guide to the respective cover of the article of footwear. In some embodiments, the curved lace guides 812, 814, 822, and 824 can be similar to the guides 250 described above with reference to fig. 10-13.

Intermediate wear prevention guides 846, 848 may also be provided between the side pairs of lace guides to prevent the laces from wearing against each other and to avoid the laces from binding around each other. In alternative embodiments, any of the lace guides of the multi-zone lacing system shown in fig. 28 can be replaced with any other suitable lace guide described elsewhere herein. The lace guides can be formed by injection molding or other methods in any suitable material, such as nylon, PVC, or PET. As discussed elsewhere herein, the lace guides are generally configured to draw the opposing covers of the article of footwear toward one another to tighten the footwear. This is typically achieved by providing the guide with a surface that causes minimal friction or wear.

In the illustrated embodiment, the third lace region advantageously employs a "double layer" of lace guides 832, 834, with lace guides 832, 834 configured to guide the first and second laces along overlapping channels while maintaining first and second laces 23a, 23b in isolation to prevent them from wearing against one another. The lower portion of the first lace 23a and a portion of the second lace 23b are shown extending through the double layer lace guide 834 and the double layer transfer lace guide 832. Figures 29A-29D illustrate an embodiment of a double layer lace guide for use with an embodiment of a multi-zone lacing system. The double-layered lace guide 834 generally comprises an upper lace guide portion 850 for guiding the first lace 23a, a lower lace guide portion 852 for guiding the second lace 23b, and a connecting portion 844 for fastening the guide to footwear. In the illustrated embodiment, each of the upper and lower guide portions 850, 852 includes an arcuate surface configured to guide the lace 23 in a substantially frictionless manner. Each arcuate portion may be similar to the guide arrangement described above with reference to fig. 10-13.

Fig. 30A-30D illustrate one embodiment of a double-layered transfer lace guide 832. Transfer guide 832 includes an upper arcuate portion 860 and a lower transfer portion 862, upper arcuate portion 860 configured to guide first lace 23 a. The upper guide portion 860 is preferably separated from the lower transfer portion in order to prevent the first and second lace 23a and 23b from being worn away from each other. The lower transfer portion 862 is generally configured to receive a portion of the tube 864 that is not axially compressible, the tube 864 abutting a lateral surface 866 of the guide 832. The transverse surface 866 also includes a hole 868, with the tube held on one side of the surface 866, the hole 868 being sized to permit the lace 23b to pass therethrough. The tube 864 can be of any suitable type, such as a bicycle cable housing or other material as described elsewhere herein. An incompressible tube portion 864 is provided over the portion of the second lace 23b between the lower portion 862 of the double layered transfer guide 832 and the lace tightening mechanism 804. This prevents the guide 832 from being pulled toward the tightening mechanism 804 when tightening the lace and ensures that the tightening force is only applied to pull the covers of the footwear toward each other. In an alternative embodiment, tube portion 864 may be removed by including a cinching mechanism within the lace guide at transfer guide 832.

In some embodiments, the connecting portion 844 of each of the double layer lace guide 834 and the double layer transfer lace guide 832 may be fastened to a strap (not shown) that can extend to a position near the heel of the article of footwear, thereby providing additional heel compression capability.

In the illustrated multi-zone lacing system, the wear guide 846 typically includes three tubes for supporting the laces 23a, 23 b. As shown, each wear guide 846 includes two intersecting diagonal conduits 870 and one linear conduit 872 for supporting the laces 23a, 23b in a substantially frictionless, non-interfering manner. In an alternative embodiment, the function of the wear guide 846 may be divided among a plurality of individual guides as desired. In alternative embodiments, any or all of the tangential tubes may be replaced by loops or straps of textile or other material that are attached to the footwear or other lace guides. In some embodiments, double-deck lace guide 834 and double-deck delivery lace guide 832 may be interconnected using a flexible strap, with a passage through the strap portions to accommodate the first and second laces. This strap may be configured to distribute compressive forces throughout the ankle region of the footwear. In some embodiments, such a band may be made of neoprene or other durable elastic material.

Each lace guide is generally configured to be secured to the article of footwear by any suitable means. For example, the lace guides may be secured to the article of footwear by stitches, adhesives, rivets, threaded or other mechanical fasteners, or the lace guides may be formed integrally with portions of the article of footwear.

Fig. 35-37C illustrate yet another embodiment of a different lacing system for tightening a first region of an article of footwear in a different manner than a second region. Figures 37A-C are generally lace doubling systems in which a lace is pulled through a slot in a first guide and hooked over a hook extending from a portion of a second guide so that the lace can be threaded through a pair of lace guides again. A third lace guide 1008 of any suitable type may also be provided on the opposite side of tightening mechanism 1000.

The lacing system shown in fig. 37A includes a lace cinch 1000 and a lace 23 extending through a plurality of lace guides, including a pair of doubled-over lace guides 1010. In some embodiments, a double-over lace guide 1010 may be provided to double the number of passes of lace 23 through a single lace guide. As shown in fig. 37C, lace 23 may be threaded twice through a given pair of lace guides 1010, thereby providing additional lacing force between the two lace guides. In some embodiments, each pair of doubled-over lace guides 1010 comprises a hook lace guide 1012 and a channel lace guide 1014.

Figure 35 illustrates one embodiment of lace guide 1014 that includes curved slot 1020. Slot 1020 is generally sized and configured to allow a user to grasp a portion of lace 23 extending through slot 1020. On either side of the slot 1020, the lace guide 1014 includes a shoulder 1022, the shoulder 1022 being configured to substantially frictionless support the lace 23 in the guide 1014. As with the other embodiments of lace guides described herein, lace guide 1014 can also include a cover 1024, with cover 1024 configured to enclose conduit 1026 with lace 23 passing through conduit 1026.

Fig. 36 illustrates one embodiment of lace guide 1012 that includes hook 1030. Hook 1030 generally extends from the interior of lace guide 1012 and is open to allow a lace to be looped around hook 1030. In some embodiments, hook 1030 has a width approximately equal to slot 1020 of slotted lace guide 1014. In some embodiments, hook 1030 may be integrally formed with lace guide 1012 using a mold, while in alternative embodiments hook 1030 may be formed separately and then attached to guide 1012. In some embodiments, hook 1030 is configured to allow a lace to slide thereon while causing minimal friction and minimal wear to the lace.

As with the other lace guides described herein, channel lace guide 1014 and hook lace guide 1012 may be made of any suitable material and may be attached to the article of footwear in any desired manner. Similarly, a number of embodiments of lace cinching mechanisms that may be used with the doubled-over lace guide lace shown in figures 35-37C are described herein. The double-over lace guide system may also be used with any of the other lace systems described herein or elsewhere.

In some embodiments, multiple pairs of lace guides may be provided on an article of footwear to provide a user with an opportunity to choose to fold the lace in half in many portions of the footwear. In other embodiments, the tightening mechanism 1000 may include a hook extending from a portion thereof to provide further versatility.

Figures 37A-37C illustrate an example of a sequence for doubling back a lace using a pair of doubled-back lace guides 1010. In the first position, as shown in fig. 37A, lace 23 is positioned through curved slot 1020. The user may grasp the lace 23 with a finger or a small tool, such as a peg. As shown in fig. 37B, the loop 1032 of lace 23 can then be pulled through the slot toward the hook lace guide 1012. Hook loop 1032 may then be positioned over hook 1030 as shown in fig. 37C to double the number of lace passes through lace guide 1010.

As discussed above, the lace 23 is preferably a highly lubricious cable or fiber having a low modulus of elasticity and high tensile strength. While any suitable tie may be used, certain preferred embodiments utilize ties formed from extended chain, high modulus polyethylene fibers. An example of a suitable tie material is currently known as SPECTRA^TMUnder the name of (1) sold by Honeywell, Morris townhe, new jersey. The extended chain, high modulus polyethylene fibers advantageously have a high strength to weight ratio, are cut resistant, and have very low elasticity. The preferred tie made of this material is tightly woven. The tight weave provides additional stiffness to the completed lace. The additional stiffness provided by the braid provides enhanced pushability so that the lace can be easily threaded through the lace guide into the spool and spool.

Laces made of high modulus polyethylene fibers are additionally preferred because of their strength to diameter ratio. The small lace diameter allows for a small spool. In some embodiments, the lace has a diameter of about.010 "to about.050", or preferably about.020 "to about.030", and in one embodiment, the lace has a diameter of.025 ". Of course, other types of lacing, including those formed of textile, polymer, or metal materials, may be suitable for use with the present footwear lacing system, as will be appreciated by those skilled in the art in light of the disclosure herein.

Another preferred embodiment is made of high modulus polyethylene fibers, nylon or synthetic materials and has a rectangular cross section. This cross-sectional shape may be formed by weaving the lace material into smooth bands, tubes, or other suitable structures. In any event, such a lace will be substantially smooth and provide a greater surface area than a cable or other similar lace, thereby reducing wear and tear with the lace guides and other footwear hardware. In addition, there is a sufficient amount of cross-sectional material to provide adequate tensile strength while allowing the lace to maintain a sufficiently thin profile for efficient winding around the spool. The thin profile advantageously allows the spool to remain small while still providing the ability to accommodate a sufficient length of lace. Of course, the strap disclosed herein is merely one example of a wide variety of different types and configurations of straps suitable for use with the strap systems disclosed herein.

Referring to fig. 38A through 51, additional embodiments of the lacing system 22 are shown. Fig. 38A and 38B are side views of an alternative cinching mechanism 1200. The fastening mechanism 1200 includes a base member 1202 that includes a housing 1203 and a mounting flange 1204 disposed near the bottom of the housing 1203. In an alternative embodiment, the flange 1204 is disposed a distance from the bottom of the housing 1203. Mounting flange 1204 may be mounted to an external structure of a piece of footwear to which tightening mechanism 1200 is attached, or may be mounted under some or all of the external structure of the footwear. The base member 1202 is preferably formed from a mold of any suitable material, as discussed above, but in one embodiment is formed from nylon. As in the other embodiments, any suitable manufacturing process that produces a fitting that fits within design tolerances is suitable for manufacturing the base 1202 and other components disclosed herein. The tightening mechanism 1200 further includes a control mechanism, such as a rotatable knob assembly 1300 mechanically coupled to the tightening mechanism. The rotatable knob 1300 is slidably movable along an axis a between two positions relative to the housing 1203.

In a first position, also referred to herein as a coupled or engaged position (shown in fig. 38A), the knob 1300 is mechanically engaged with an internal gear mechanism disposed within the housing 1203, as described more fully below. In a second position, also referred to herein as a non-coupled or disengaged position (shown in fig. 38B), the knob 1300 is disposed upwardly relative to the first position and is mechanically disengaged from the gear mechanism. Disengagement of the knob 1300 from the internal gear mechanism is preferably accomplished by pulling the control mechanism outwardly along axis a, away from the mounting flange 1204. Alternatively, the components may be disengaged using a button or release, or a combination of button and knob 1300 rotation, or variations thereof, as will be understood by those skilled in the art, as described herein above.

FIG. 39 shows a top perspective exploded view of one embodiment of a tie-down mechanism 1200. The embodiment shown in fig. 39 shows a base unit 1202, a spool 1240 and a knob assembly 1300. Spool 1240 is generally configured and disposed within housing 1203. Knob assembly 1300 may then be assembled with housing 1203 and spool 1240 to provide tightening mechanism 1200. The tightening mechanism 1200 may also be referred to herein as a lace arrangement, lace lock, or more simply, lock.

Fig. 40A-40C illustrate one embodiment of a base member 1202. The base 1202 includes a housing 1203 and a mounting flange 1204. Preferably, the flange 1204 extends circumferentially around the housing 1203. In an alternative embodiment, the flange 1204 extends only partially around the circumference of the housing 1203 and may include one or more distinct portions. Although the flange 1204 is shown as being circular or ovular in shape, the flange 1204 may also be rectangular, square, or any of a number of other regular or irregular shapes. The flange 1204 preferably includes a groove 1208 extending substantially the length of the outer perimeter of the flange. The middle of the slot 1208 is preferably thinner than the remainder of the flange 1204 to facilitate attaching the base 1202 to the footwear by stitching. Although stitching is preferred, the base 1202 may be secured using any suitable method, such as with adhesives, rivets, threaded fasteners, etc., or any combination thereof. For example, an adhesive may be applied to lower surface 1232 of base member 1202. Alternatively, the mounting flange 1204 can be removably attachable to the footwear, such as by a releasable mechanical adhesive structure in the form of cooperating hook and loop structures. The contour of the flange 1204 is preferably curved with the portion of the footwear to which the flange 1204 is attached. This profile is shown in fig. 38A and 38B and fig. 45A and 45B. In some embodiments, the contour is smooth. The flange 1204 also preferably has sufficient spring force to at least partially bend with the force causing the footwear structure to which the flange 1204 is mounted to bend.

The housing 1203 of the base member 1202 is generally a hollow cylinder having substantially vertical walls 1210. The housing wall 1210 may include a minimal taper outward from the uppermost surface 1332 of the housing 1203 to the base of the housing 1203 toward the flange 1204. The housing 1203 preferably includes beveled teeth 1224 formed onto its uppermost surface 1332, such as found on a ratchet wheel, as has been described above. The base member teeth 1224 may be formed during the molding process or may be cut into the housing after the molding process, each tooth defining an angled portion 1226 and a substantially vertical portion 1228. In one embodiment, the vertical portion 1228 can include a back-cut vertical portion 1228, wherein the vertical portion 1228 is less than 90 degrees, as described below.

In one embodiment, the angled portion 1226 of each tooth 1224 allows relative clockwise rotation of a cooperating control member, such as the knob assembly 1300, while not allowing relative counterclockwise rotation of the control members. Of course, the direction of the teeth may be reversed as desired. The number and spacing of the teeth 1224 control the accuracy of the possible adjustments, and those skilled in the art can design the specific number and spacing to use the intended purpose in light of the disclosure herein. However, in many applications where precise lace tension adjustment is desired, the inventors have found that about 20 to 40 teeth is sufficient to provide adequate lace tension adjustment.

The base member 1202 additionally includes a pair of strap entry holes 1214 to allow entry of each end of the strap through the inner strap opening 1230. Lace access hole 1214 and inner lace opening 1230 preferably define a long lace channel corresponding to spool annular groove 1240. Preferably, the strap entry holes 1214 are disposed on the vertical walls 1210 of the housing 1203 directly opposite each other. As discussed above, a harder material may be added as an insert or coating to make the strap entry hole of the base member 1202 stronger to reduce wear of the strap rubbing against the entry hole 1214 of the base member 1202. In addition, the location of the access hole may be rounded or chamfered to provide a greater area of contact with the strap, thereby further reducing the pressure wear effect of the strap rubbing against the base unit. In the illustrated embodiment, the strap opening extension 1212 included with the base member 1202 includes a rounded entry hole edge 1216 to provide additional strength to the housing 1203 in the area of the strap entry hole 1214. FIG. 41 shows a modified entry hole edge 1216. As described above, the lace guides can be integral with the base member 1202 and can be configured according to the particular application of the lacing system 22. In fig. 47B, an embodiment with integrated lace guides is shown attached to footwear.

The inner bottom surface 1220 of the base member 1202 is preferably highly smooth to allow for efficient sliding engagement of the mating features therewith. Accordingly, in one embodiment, a washer or bushing (not shown) is disposed in the cylindrical housing portion 1203 of the base member 1202 and may be formed of any suitable smooth polymer, such as PTEF, or may be formed of a smooth metal. Alternatively, the inner bottom surface 1220 of the base member 1202 may be coated with any number of coatings (not shown) designed to reduce the coefficient of friction, thereby allowing any components in contact with its common surface to slide easily. One advantage of the illustrated embodiment is that the need for separate moving parts to manufacture the cinching mechanism 1200 is reduced. The reduction of parts reduces manufacturing costs and preferably results in a lighter weight mechanism. In general, the tightening mechanism 1200 is small and fits snugly against some of the moving parts. The light weight, fewer moving parts also reduces the friction generated on the internal components of the lacing system 1200 during use.

The inner face 1218 of the housing 1203 is preferably substantially smooth to facilitate winding of the lace on a spool positioned within the housing 1203 during operation. Inner face 1218 cooperates with annular groove 1256 to secure the wound lace when spool 1240 is inserted into housing 1203. Preferably, the material selected for the inner face 1218 is adapted to reduce friction if the tether rubs against a surface when wrapped into the outer shell 1203 or released from the outer shell 1203. Fig. 40B shows a top view of base member 1202. The base 1202 preferably includes a central axial opening 1222. In a preferred embodiment, the opening 1222 is adapted to receive a threaded insert 1223. Insert 1223 is preferably metal or some other material that provides suitable strength for securely retaining axial pin 1360 (e.g., FIG. 39).

Fig. 40C shows a groove 1286 that is preferably included in base member 1202. Groove 1286 further reduces the material used in the illustrated embodiment, thereby reducing the weight of the complete tie-down mechanism 1200 and providing an improved molded article by providing a substantially similar wall thickness throughout base member 1202. Also shown is a part number 1236. Indicia 1236 may be used to indicate the "handedness" of a particular component. In some applications, i.e., on a pair of footwear having a unit for use with a right foot and a unit for use with a left foot, it may be desirable for lacing arrangement 1200 associated with the footwear to operate in different directions. Indicia 1236 help provide a coordinated fit for each lacing arrangement 1200. Indicia 1236 may be used on some or all of the components described herein. Indicia 1236 can be formed during the molding process or painted onto the part.

With additional reference to fig. 39 and 42A-42E, spool 1240 is provided and configured to be located within housing 1203 of base member 1202. Spool 1240 is preferably molded from any suitable material, as discussed above, but in a preferred embodiment spool 1240 is formed from nylon and may include a metal insert, preferably along the axis therebetween. In alternative embodiments, spool 1240 is cast or molded from any suitable polymer or is formed from a metal, such as aluminum. Spool 1240 preferably includes an upper flange 1253, a lower flange 1242, and a substantially cylindrical wall 1252 therebetween. An intermediate axial opening 1286 extends through spool 1240 and includes an interior sidewall 1288. Bottom surface 1254 of upper flange 1253 cooperates with the exterior surface of cylindrical wall 1252 and upper surface 1244 of lower flange 1242 to form annular recess 1256. Annular groove 1256 is advantageously adapted to receive the lace wound on the spool 1240 as the lace is wound on the spool.

In a preferred embodiment, bottom surface 1254 of upper flange 1253 and upper surface 1244 of lower flange 1242 are both angled with respect to the horizontal axis of spool 1240. As shown in FIG. 42B, the distance between the surfaces near cylindrical wall 1252 is less than the distance between the surfaces as measured from the outer diameter of the flange. As lace 23 is wound on spool 1240, the effective diameter of the combined lace and spool increases. Advantageously, as tension is applied to the lace 23, the coiled lace 23 can unravel, thereby minimizing the effective diameter of the spool plus lace. The smaller the effective diameter, the greater the torsional force acting on lace 23 when knob 1300 is rotated. In an alternative embodiment, spool 1240 includes one or more additional flanges to define additional annular grooves.

Preferably, the periphery of upper surface 1260 of upper flange 1253 is configured to include helical teeth 1262. If spool 1240 is made from a mold, angled teeth 1262 may be formed during the molding process, and each angled tooth 1262 defines an angled portion 1264 and a substantially vertical portion 1266 measured from upper surface 1260. The vertical portion 1266 is preferably back-cut so as to be slightly less than 90 degrees, preferably ranging from zero degrees (0) to twenty degrees (20) less than ninety degrees (90). More preferably, the angle is one (1) to five (5) degrees less than 90 degrees. Most preferably, the angle is less than 90 degrees by about three degrees (3). In one embodiment, vertical portion 1266 of each tooth 1262 cooperates with a tooth formed on the control member, such as knob tooth 1308, to cause relative counterclockwise rotation of spool 1240 as the cooperating control member is rotated counterclockwise, thereby winding lace around cylindrical wall 1252 of spool 1240. Of course, the direction of the teeth may be reversed as desired. A small or back-cut angle of less than 90 degrees is preferred because this may increase the strength of the mating relationship between the spool teeth 1262 and the control member. As lace tension increases, spool 1240 and knob 1300 may tend to disengage. Back cutting the vertical portion of the tooth helps prevent inadvertent disengagement.

Advantageously, spool 1240 is dimensioned so as to reduce the overall size of tightening mechanism 1200. The ratio of the diameter of cylindrical wall 1252 of spool 1240 to the diameter of control knob 1300 can be adjusted to affect the torsional force generated within tightening mechanism 1200 during the winding process. As lace 23 is wound around spool 1240, its effective diameter increases, as does the torsional force generated by rotating knob 1300. Preferably, the twist force is maximized while maintaining the compact size of the cinch lock 1200. For purposes of non-circular cross-section, diameter as used herein refers to the diameter of the most suitable circle, which includes cross-sections lying in planes transverse to the axis of rotation.

In many embodiments of the present invention, the knob 1300 will have an outer diameter of at least about 0.5 inches, typically at least about 0.75 inches, and in one embodiment, at least about 1.0 inch. The outer diameter of the knob 1300 is typically less than about 2 inches, preferably less than about 1.5 inches.

The cylindrical wall 1252 defines a base of the bobbin having a diameter that is generally less than 0.75 inches, and generally no more than 0.5 inches, and in one embodiment the diameter of the cylindrical wall 1252 is about 0.25 inches.

The depth of the annular recess 1256 is generally less than 1/2 inches, generally less than 3/8 inches, and in certain embodiments, no more than about 1/4 inches. In one embodiment, the depth is approximately 3/16 inches. The width of the annular recess 1256 around its opening is generally no more than about 0.25 inches, and in one embodiment no more than about 0.13 inches.

Knob 1300 typically has a diameter that is at least about 300%, preferably at least about 400%, of the diameter of cylindrical wall 1252.

The diameter of the lace used in cooperation with the cylindrical wall 1252 described above is generally small enough so that the annular recess 1256 can accommodate a lace of at least about 14 inches, preferably at least about 18 inches, in some embodiments at least about 22 inches, and in one embodiment about 24 inches or more, excluding the connection end of the lace. At the full winding end of the winding cycle, the outer diameter of the cylindrical stack of wound lace is less than 100% of the diameter of the knob 1300, and, preferably, less than about 75% of the diameter of the knob 1300. In one embodiment, the outer diameter of the fully wound lace is less than about 75% of the diameter of the knob 1300.

By making the effective spool diameter less than about 75% of the diameter of the knob 1300, even when the spool is fully wound, sufficient leverage is maintained such that gearing or other leverage-enhancing structures are not necessary. As used herein, the term effective spool diameter refers to the outer diameter of the windings of lace wound on the cylindrical wall 1252, which increases as additional lace is wound around the cylindrical wall 1252, as will be appreciated by those skilled in the art.

In one embodiment, about 15 turns around cylindrical wall 1252 will accommodate about 24 inches of lace. Typically, at least about 10 turns, often at least about 12 turns, and preferably at least about 15 turns of the lace around cylindrical wall 1252 will still result in an effective spool diameter of no more than about 65% or about 75% of the diameter of knob 1301.

Laces having an outer diameter of less than about 0.060 inches are often used, and laces having an outer diameter of less than 0.045 inches are often used. In some embodiments, a lace diameter of less than about 0.035 will be used.

Side edges 1258 and 1242 of upper flange 1253 and lower flange 1248 are adapted to slidably engage inner wall surface 1218 of housing 1203 of base member 1202. The sliding engagement with inner wall surface 1218 helps stabilize spool 1240 within housing 1203. Similarly, interior side wall 1288 of axial opening 1286 of spool 1240 slidingly engages axial body 1370 of axial pin 1360 to stabilize spool 1240 during use of lacing apparatus 1200. Lower surface 1246 of lower flange 1242 may be configured to be efficiently slidably engaged with interior bottom surface 1220 of base member 1202. In fig. 42C, the lower surface 1246 is shown as being substantially smooth. In an alternative embodiment, the lower surface 1246 may have a lip (not shown) that provides a small surface area that contacts the bottom surface 1202 of the base member 1202.

As shown in fig. 42A-42B, lower flange 1242 of spool 1240 preferably includes lace voids 1250. The lace voids 1250 facilitate the attachment of a lace to a spool as described below. Lace voids 1250 also facilitate insertion of spool 1240 within housing 1203 after lace 23 is attached to spool 1240. Preferably, the edges of the lace voids 1250 are rounded. The rounded edges reduce the likelihood of the lace catching on the voids, which may undesirably tie the lace. Preferably, all edges directly contacting the ligament are preferably rounded. This is particularly advantageous when the lace is slid against the edge.

As described in detail above, spool 1240 may include one or more annular recesses 1256, with annular recesses 1256 configured to receive lace 23. Preferably, the ends of lace 23 are fixedly or removably attached to spool 1240 using any of a number of suitable attachment methods, including the use of set screws, crimper adhesives. In the preferred embodiment shown in fig. 42E, lace 23 is removably secured to spool 1240. Upper flange 1253 of spool 1240 preferably includes two sets of three retaining holes (see fig. 42A) adapted to receive lace 23. The interior sidewall 1268 of the upper flange 1253 cooperates with the sidewall 1274 of the intermediate divider 1272 to define a knotting aperture 1278. In a preferred embodiment, side walls 1268 and 1274 include one or more lace notches 1276 to facilitate insertion of lace 23 into the retention hole. In alternative embodiments, lace notch 1276 is not included.

The strap 23 is preferably threaded through a strap hole 1214 in the base member 1202 to secure the strap 23 to the spool 1240. Lace 23 exits inner lace opening 1230 of housing 1203 and is directed toward spool 1240. Lace 23 is then threaded through lace void 1250 and up through access hole 1280 in upper flange 1253. Lace 23 then passes down through loop hole 1282a and back up through loop hole 1282 b. Thus, the loop formed by a portion of lace 23 is disposed over upper flange 1253 and between entry hole 1280 and annular hole 1282 a. The end of lace 23 is threaded through the loop and tension is applied to a portion of lace 23 extending downwardly from entry hole 1280 to tighten knot 1292 thereby created. Knot 1292 is preferably positioned by passing the end of lace 23 through the loop from the outside inward so that it is located within knot chamber 1278, as shown in fig. 42E. A second junction 1292 is similarly formed. Advantageously, wall 1252 of spool 1240 may also include lace groove 1284. After lace 23 is tied to spool 1240, lace groove 1284 captures a portion of lace 23 that extends into annular groove 1256. By containing this portion of lace 23 within wall 1252, the lace 23 can be more dexterously wound around spool 1240 with less compressive and pressure forces on the portion of lace 23 extending into annular recess 1256. Lace groove 1284 further minimizes the diameter of spool 1240 to maximize the torsional force that may be applied to lace 23, as discussed above. In an alternative embodiment, lace groove 1284 is not included.

While the above-described method of securing lace 23 to spool 1240 is preferred, the inventors contemplate other methods of connecting the laces. The above-described method of connecting lace 23 to spool 1240 is advantageous because it allows for a simple, secure connection to spool 1240 without the need for additional connecting components. This reduces weight and reduces the assembly time required to manufacture footwear that includes fastening mechanism 1200, as described herein. Further, this type of connection allows for simplified, easy replacement of the lace 23 when the lace 23 is worn out.

Referring now to fig. 39, 43A and 43B, tightening mechanism 1200 further has a control knob assembly 1300, the control knob assembly 1300 being configured to incrementally rotate in a forward rotational direction, i.e., in a rotational direction that winds lace 23 onto spool 1240. To this end, the control knob 1300 preferably includes a series of integrally mounted pawls 1302, the pawls 1302 engaging a corresponding series of teeth 1224 located on the housing 1203 of the base 1202. Pawl 1302 preferably engages base teeth 1224 only when control knob 1300 is in the coupled or engaged position, as shown in fig. 38A. When the knob 1300 is in the engaged position, the tooth/pawl engagement prevents the knob 1300 and mechanically coupled spool 1240 from rotating in a rearward direction (i.e., in a direction opposite to the direction in which lace 23 is wound onto spool 1240). This configuration prevents a user from inadvertently winding the control knob 1300 backwards, which would cause the lace 23 to become tied or entangled in the spool 1240. In an alternative embodiment, pawl 1302 may be configured to allow incremental rotation of knob 1300 in the opposite direction, such as altering the angled surface 1304 of pawl 1302. This embodiment is advantageous because it further reduces the tension on the lace.

The knob assembly 1300 preferably includes a knob 1301, a spring assembly 1340, and a cover member 1350. As shown in fig. 43A, the bottom surface of knob 1301 further includes teeth 1308 for engaging with spool teeth 1262 of spool 1240. The knob tooth 1308 includes an angled portion 1310 and a vertical portion 1312. One or more cover engagement openings 1314 extend through the knob 1301 to facilitate coupling the cover 1350 to the knob 1301. Cover 1350 preferably includes one or more downwardly extending engagement arms 1352 (fig. 39) that can cooperate with one or more engagement openings 1324. In a preferred embodiment, the arms 1352 are heat-set in place. Cover 1350 may be permanently or removably coupled to knob 1301 in any of a variety of ways, as will be appreciated by those skilled in the art. For example, in an alternative embodiment, the engagement arms 1352 include prongs or protrusions at their ends to removably secure the cover member 1350 to the knob 1301. As shown in fig. 39, upper surface 1354 of cover 1350 may advantageously include advertising indicia 1356, which advertising indicia 1356 may be in the form of raised letters or symbols, and optionally may be visually colored differently than the remainder of upper surface 1354. In this way, the tightening device can be used as an advertising tool. In other embodiments, the upper surface 1354 does not include indicia 1356.

The external engagement surface 1319 of knob 1301 is preferably formed with knurling 1318 or some other friction enhancing feature. In a preferred embodiment, the external engagement surface 1317 is made of a softer material than the rest of the knob 1301 to enhance the feel of the knob 1301 and to facilitate manipulation of the lacing arrangement 1200 to apply tension to the lace 23.

As shown in fig. 39 and 43B, the upper side of the knob 1301 is configured to retain the spring member 1340. Preferably, spring member 1340 is of unitary construction and includes engagement arms 1342. In a preferred embodiment, engagement tabs 1322 of knob 1301 cooperate with outer side walls 1326 of intermediate engagement projection 1324 to retain spring 1340. As shown in fig. 45A and 45B, engagement arms 1342 are preferably retained within knob 1300, but are secured so that they can move outwardly within cavity 1334 when tightening mechanism 1200 is engaged or disengaged. FIG. 46 shows a top perspective cross-sectional view of tightening mechanism 1200 in a disengaged position.

In a preferred embodiment, axial pin 1360 secures knob assembly 1300, spool 1240, and base member 1202. Axial pin 1360 is preferably made of a metallic material or other material of sufficient strength to withstand the forces exerted on tightening mechanism 1200. Axial pin 1360 also preferably includes multiple regions of varying diameters, including cover 1364 having upper surface 1363, upper side engagement surface 1364, lower side engagement surface 1366, and lower surface 1367. Upper side engagement surface 1364 preferably tapers inwardly from upper surface 1363 to lower side surface 1366. Lower side engagement surface 1366 preferably tapers inwardly from upper side engagement surface 1364 to lower surface 1367. Preferably, the diameter of axial pin 1360 is largest along the circumference where upper and lower side engagement surfaces 1364 and 1366 intersect. The diameter of upper surface 1363 is preferably greater than the diameter of lower surface 1367.

Upper surface 1363 of cover 1350 also preferably includes one or more engagement holes 1374 for rotating pin 1360 into threaded engagement with base member 1202. In other embodiments, a single centrally located engagement hole is used with a non-circular opening, as will be appreciated by those skilled in the art. Upper surface 1363 may also include indicia 1376. In an alternative embodiment, marker 1376 is not included.

An upper sleeve 1368 is disposed adjacent and below the cover 1362. The diameter of upper sleeve 1368 is preferably smaller than the diameter of lower surface 1367. Pin body 1370 is preferably disposed adjacent and just below upper sleeve 1368. The diameter of pin body 1370 is preferably smaller than the diameter of upper sleeve 1360. Finally, threaded extension 1372 preferably extends downwardly from the lower surface of pin body 1370. Although extension 1372 is a threaded extension, other mating or engaging means may be used to couple pin 1360 with base 1202.

Axial pin 1360 includes multiple diameters to correspond to different inner diameters of the axial openings in knob 1300, spool 1240, and base member 1202, respectively. The corresponding diameters of these components help stabilize the cinching mechanism 1200. Pin body 1370 is adapted to slidably engage an interior sidewall 1288 of seal opening 1286 of spool 1240. Upper sleeve 1368 is adapted to slidably engage inner wall 1330 of axial opening 1316 of knob 1301. Threaded extension 1372 couples with insert 1223 of base member 1202 to secure axial pin 1360 to base member 1202. As will be appreciated by those skilled in the art, axial pin 1360 may be permanently or removably attached to base member 1202. For example, an adhesive may be used, alone or in combination with threads.

Fig. 44A and 44B are top views of tightening mechanism 1200 in an engaged position and a disengaged position, respectively. Referring now to fig. 45A and 45B, the knob 1300 is shown exhibiting mobility between two positions, a coupled or engaged position (fig. 45A) and an uncoupled or disengaged position (fig. 45B). In the uncoupled position, lace 23 can be manually removed from spool 1240, for example, by applying tension to lace 23 in a direction away from tightening mechanism 1200.

Advantageously, the upper sleeve 1368 of axial pin 1360 has a diameter greater than the inner diameter of axial opening 1286 of spool 1240. Likewise, upper sleeve 1368 of axial pin 1360 acts as an upper limiter of movement of spool 1240 along axis A, as can be seen in FIG. 45A. Movement along axis a is limited such that when the knob 1300 is in the disengaged position, as shown in fig. 45B, the knob teeth 1308 are disengaged from the spool teeth 1262, thus allowing the spool 1240 to rotate freely in the disengaged position. In the disengaged condition, lace 23 is manually removed from spool 1240. In a preferred embodiment, only a single adjustment device, e.g., knob 1300, is required in order to actuate tightening mechanism 1200. The adjustment device is pushed in to tighten the lacing system 22 and pulled out to loosen the lacing system 22.

In a preferred embodiment, spring engagement arm 1342 engages an upper side engagement surface 1364 of cover 1362 in the uncoupled position and a lower side engagement surface 1366 in the coupled position. In the coupled position, arm 1342 engages lower side engagement surface 1366 to bias knob 1300 in the coupled position. In the uncoupled position, arm 1342 engages upper side engagement surface 1364 to bias knob 1300 in the uncoupled position. While in the present embodiment, the spring 1340 biases the knob 1300 in the coupled and uncoupled positions, there are other options as will be appreciated by those skilled in the art. For example, the knob 1300 can only be biased in the engaged position so that the knob can be pulled out of engagement with the spool 1240, however, once released, the knob 1300 slidably returns to the engaged position.

In a preferred embodiment, knob 1300 will be biased in the coupled and uncoupled positions, requiring the user to push or pull the knob against the bias in order to engage or disengage, respectively, with tightening mechanism 1200. Advantageously, engagement or disengagement with tightening mechanism 1200 is accompanied by a "click" where the surface position has changed. Tightening mechanism 1200 may also include visual indicia indicating that the mechanism is disengaged, such as a colored block exposed from under the knob when in the disengaged position. Audible or visual indicia indicating that the mechanism is engaged or disengaged helps the lacing system described herein to be easy for the user to use.

Fastening mechanism 1200 can be removably or securely mounted to the footwear in a variety of positions, including the front, back, top, and side surfaces. The base member 1202 shown in fig. 38A-41 is adapted to be attached to the side of a boot or shoe. The tightening mechanism 1200 shown in fig. 47A-47C is securely sewn to the upper near the eyelet of the shoe. The lace guide can be included on the base 1202 of the mechanism 1200, as shown in fig. 47B, or can be separate. In some embodiments, all of fastening mechanism 1200 is secured substantially entirely within the footwear structure, leaving only a small portion of knob 1300 and housing 1203 exposed. In some such embodiments, lace holes 1214 are locations substantially along the axis of the eyelets of attachment mechanism 1200 (see fig. 47B). When mechanism 1200 is attached in this manner, flange 1204 preferably extends in a direction opposite lacing hole 1214, thereby allowing mechanism 1200 to be positioned at or near the upper in the vicinity of the tongue. Mechanism 1200 may also be disposed on other areas of footwear, including the sole or toe portions. Lacing system 22 also includes tongue guide 1380 and lace guide 1392, as will be discussed in more detail below.

Fig. 48B and 49B illustrate an alternative preferred embodiment of a fastening mechanism 1200 that includes an improved base member 1202. Base member 1202 is configured with a lower housing 1208 and an upper housing 1203. The lower housing 1208 slopes outwardly from the upper housing 1203 to the flange 1204. The uppermost portion of lower housing 1208 preferably includes a protective lip 1290. In some embodiments, the protective lip 1290 extends partially over the exterior engagement surface 1319 of the knob assembly 1300 and extends immediately around a circumferential portion of the knob 1300. In an alternative embodiment, the lip extends completely around the circumference of the knob. In still other embodiments, the lip extends only partially around the circumference of the knob, but extends upwardly over substantially the entire width of the exterior engagement surface 1319 of the knob 1300.

In the embodiment shown in fig. 48A and 48B, lower housing 1208 preferably includes lace channels 1238 that lead from rear surface 1232 of base member 1202 to lace holes 1214. As shown in fig. 48A, the tether hole 1214 preferably extends through the upper surface 1332 of the upper housing 1203. The flange 1204 and lower housing 1208 are defined in a substantially curved manner to accommodate attachment surfaces with an inherently large curvature, such as at the rear of a boot or shoe.

The base member 1202 shown in figures 48A-49B is preferably adapted to be attached to a boot or boot rear. The tightening mechanism 1200 shown in fig. 50A and 50B is securely stitched to the rear of the shoe. Advantageously, after passing through the uppermost tongue guide 1380, lace 23 enters lace guide 1392 and is guided around the ankle portion of the shoe toward tightening mechanism 1200. Lace guide 1392 is preferably made of a low sliding resistance polymer, such as teflon or nylon, and preferably includes rounded edges. The uppermost lace guide 1392 also preferably has only one entry point on each side of the footwear, the exit point being directly coupled to the lace channel 1338 of the rear-mounted tightening mechanism 1200.

Lacing system 22 preferably includes a tongue guide 1380, tongue guide 1380 being shown in greater detail in fig. 51. The tongue guide 1308 preferably includes a mounting flange 1382, sliding surfaces 1384a and 1384b, and an intermediate cover 1388. The intermediate cover 1388 is preferably disposed in a raised manner above the sliding surface 1384 by one or more standoffs 1390. The sliding surfaces 1384a and 1384b are preferably arranged in different planes so as to form a generally vertical flange 1386 therebetween. The different planes of the sliding surface 1384 help to reduce friction by limiting the sliding of the lace 23 against itself. Mounting flanges 1382 may be sewn under one or more layers of the tongue or on the outer surface of the tongue. In alternative embodiments, the tongue guide 1380 is attached to the tongue using adhesives, rivets, or the like, or combinations thereof, as will be appreciated by those skilled in the art. The legs 1390 are preferably angled to accommodate different entry and exit directions of the strap 23 as the strap 23 enters the intermediate lid portion 1388.

As with the other components of the lacing system described herein, tightening mechanism 1200, the tongue guide, and other lacing guides described above in connection with tightening mechanism 1200 may be made of any suitable material and may be attached to the footwear in any suitable manner. Various components of the lacing system may be used in part or in whole with other components or systems described herein. As discussed above, the lace 23 may be formed from any of a number of polymeric or metallic materials, or combinations of such materials, that exhibit sufficient axial strength and flexibility for the present application. In a preferred embodiment, tether 23 comprises a multi-strand cable, such as a 7 strand by 7 strand cable made of stainless steel. To reduce friction between the lace 23 and the guide members through which the lace 23 slides, the outer surface of the lace 23 is preferably coated with a lubricious material, such as nylon or teflon. The coating also tightens the wires of the multi-strand cable so that the lace is easily inserted into the lace guides of the lace and easily connected to the gear mechanism within the lace assembly 1200. In a preferred embodiment, the lace 23 has a diameter ranging from about 0.024 inches to about 0.060 inches, including a coating of lubricious material. More preferably, lace 23 has a diameter in the range of about 0.028 to about 0.035. In one embodiment, lace 23 is preferably about 0.032 inches in diameter. Lace 23, which is at least five feet in length, fits most footwear sizes, although greater or lesser lengths may be used depending on the design of the lacing system. For example, lacing systems used with running shoes may preferably use laces of about 15 inches to 30 inches.

Referring to fig. 52A-59B, additional embodiments of the lacing system 22 are shown. Fig. 52A and 52B are top and perspective views, respectively, of alternative tightening mechanism 1400. Tightening mechanism 1400 may also be referred to herein as a lacing arrangement, a lace lock, or more simply a lock. As with other embodiments provided herein, tightening mechanism 1400 may be configured to be disposed in any of a variety of locations on the footwear, including in the ankle area (e.g., on a snowboard boot or hiking boot with ankle support), on the tongue (if the footwear includes a tongue), on the instep area of the footwear, or on the rear of the footwear. It is preferably molded from any suitable material, as discussed above, but in one embodiment includes nylon, metal, and rubber. As in the other embodiments, any suitable manufacturing process that produces a fitting within the design tolerances is suitable for manufacturing tightening mechanism 1400 and its components.

FIG. 53 illustrates a top perspective exploded view of one embodiment of tightening mechanism 1400. The embodiment shown in fig. 53 includes a base member (or bayonet) 1402, a housing assembly 1450 including a spool assembly 1480, and a control mechanism, such as a rotatable knob assembly 1550. Housing 1450 is configured to fit within inner cavity 1406 of bayonet 1402, while spool assembly 1480 is generally configured within inner cavity 1462 of housing 1460. Knob assembly 1550 may be mechanically coupled to housing 1460 to provide tightening mechanism 1400. In some embodiments, tie-down mechanism 1400 further includes coil assembly 1600. Rotatable knob assembly 1550 is preferably slidable along axis a between two positions relative to housing 1560.

In an alternative embodiment, the spool assembly 1480 is off-axis from the knob assembly 1550. This allows for a mechanically adjusted tightening mechanism 1400 that maintains a low profile relative to the surrounding mounting surface.

Bayonet 1402 may include mounting flange 1404 useful for mounting tightening mechanism 1400 to an exterior structure of a shoe. Preferably, the flange 1404 extends circumferentially around the inner and outer sections 1412 and 1414. In an alternative embodiment, lip 1404 extends only partially around the circumference of sections 1412 and 1414 and may include one or more different portions. Although flange 1404 is shown as being ovular, it can also be rectangular, circular, square, or any of a number of other regular or partially regular shapes. The flange 1404 may be similar to the flange 1204 disclosed herein above.

Mechanism 1400 may be mounted on the exterior surface of the footwear or under some or all of the footwear structure by stitching, hook or loop fastener rivets, or the like. While it is not necessary to manufacture tightening mechanism 1400 from different components, it is advantageous to do so. For example, portions of tightening mechanism 1400 may be manufactured at different locations and then combined together to form a complete mechanism. In one example, bayonet 1402 may be secured to footwear that is detached from the remainder of tightening mechanism 1400. Footwear having bayonet 1402 may then be transported to one or more locations where the remainder of tightening mechanism 1400 is installed. Further, modularity allows a user of an article comprising mechanism 1400 to replace individual components as needed.

As with other embodiments disclosed herein, tightening mechanism 1400 may be mounted in a number of different locations on the footwear, including but not limited to on the tongue, on the ankle portion (if high-top, such as a hiking boot or snowboard boot), on the instep portion of the footwear, or on the rear of the footwear. If the footwear includes a bootie, the tightening mechanism may be mounted on the bootie rather than on the surface of the footwear. If the footwear includes a cap or other covering that extends across the instep area, mechanism 1400 may be mounted on or near the cap or other covering. Embodiments of tightening mechanism 1400 may be used with some or all of the various lace components disclosed herein above. For example, the tightening mechanism may be used with the multi-zone lacing system 800 shown in FIG. 28. Embodiments of mechanism 1400 may be used in place of first lace tightening mechanism 802 or second lace tightening mechanism 804, where first lace tightening mechanism 802 or second lace tightening mechanism 804 are arranged to tighten first lace 23a and second lace 23 b.

Referring now to FIGS. 54A through 54F, a number of different views of bayonet 1402 are shown. Side views, such as 54E and 54I, represent two sides of the illustrated embodiment. Typically, tightening mechanism 1400 is symmetrical along its central axis (except for markings at different locations on the mechanism). This embodiment of bayonet 1402 is configured for use at a location remote from the tongue or midline of the lacing system, such as on the sides of the footwear or at the rear of the footwear. Interior section 1412 is disposed on the side facing the footwear, preferably extending further along flange 1404 than section 1412 to accommodate lace exit hole 1410. FIG. 54A is a rear view of bayonet 1402. FIG. 54B is a rear perspective view of bayonet 1402 showing lace entry holes 1410. Figure 54C is a top view of bayonet 1402 showing lace exit hole 1408. Lace 23 can be advanced through lace entry aperture 1410 and withdrawn through lace exit aperture 1408 to connect to shell 1450 (see fig. 55 of shell 1450). FIG. 54D is a front perspective view of bayonet 1402. Figure 54E is a side view of bayonet 1402 illustrating lace entry hole 1410 disposed on an interior cross-section 1412 of bayonet 1402. FIG. 54F is an end view of bayonet 1402 showing entry hole 1410. Figure 54F also shows the general layout of the inner and outer sections 1412, 1414 of a particular embodiment.

In a preferred embodiment, lace apertures provided rearward or within bayonet 1402 facilitate lace guides disposed within the footwear structure. For aesthetic or structural reasons, it is important to have lace 23 completely hidden under the surface of the footwear. As will be appreciated, lace access hole 1410 can be readily positioned at a variety of other locations on interior cross-section 1412 that have a similar effect.

Fig. 54I through 54K illustrate various views of an alternative bayonet 1402. This embodiment may be preferred for use with a tightening mechanism mounted on the tongue, mounted on the front or on the midline, or in another location where it may be advantageous to have a lace 23 disposed on an exterior surface of the structure to which tightening mechanism 1400 is mounted. Side strap entry hole 1410 is provided in outer section 1414 of bayonet 1402. Accordingly, the outer section 1414 is deeper than the inner section 1412. Lace exit hole 1408 again allows lace 23 to be coupled to housing 1450 through bayonet 1402. It is also possible to form the bayonet with inner and outer sections 1412, 1414 of the same depth.

Fig. 55A-55D illustrate one embodiment of a housing 1450 coupled with a knob assembly 1550. Fig. 55A is a rear view showing support plate 1468 fastened to housing 1462. In the illustrated embodiment, the support plate 1468 is removably secured with screws. However, in alternative embodiments, any of a number of other fastening devices may be used, removable or permanent, including rivets, snaps, or pins, as will be appreciated by those skilled in the art. Support plate 1468 provides a backing for housing 1462. As shown in FIG. 53, spool 1482 is configured to fit within cavity 1464 and, in this embodiment, against support plate 1468. Similarly, a plate 1454 is secured to the rear side of the housing 1462 to provide a support for the shaft 1456 (as shown in fig. 53). The upper surface of housing 1464 is covered by a cover 1490 which includes access holes 1496 and housing teeth 1492. In a preferred embodiment, the cover 1490 is removably secured to the housing 1462 by a combination of screws 1492 and lip flanges 1491. With respect to this and other embodiments, other means may be utilized, as disclosed in the preceding sections herein. Preferably, cover 1490 is removably securable to allow access to internal components of tightening mechanism 1400, such as spool assembly 1480. This cover facilitates replacement of various components and also facilitates replacement of the strap 223 within the housing 1460 and spool 1480.

Fig. 56A-56D illustrate another embodiment of a housing 1450 coupled with a knob assembly coupling 1550, differing from fig. 55A-55D only in that this illustrated embodiment includes a coil assembly 1600. As shown in fig. 53, the coil assembly is comprised of a spring punch 1608 disposed in the center of a coil spring 1606. Punch 1608 and spring 1606 are disposed within coil backing 1604, which in turn is secured to housing 1462 by coil screw 1602. Coil assembly 1600 operates in a manner similar to the coiled strap described in the upper section herein. The intermediate punch post 1610 engages 1500 the engaged center section of spool 1482. Likewise, as the spool 1482 is rotated by interaction with the pinion gear 1552 of the knob assembly 1550, the spring punch 1608 is also rotated. As discussed above, the spring punch 1608 is coupled to the coil spring 1606 such that pulling the lace 23 from the spool 1482 biases the spring 1606. When lace 23 is released, spring 1606 rotates spool 1482 causing it to wind up additional lace length.

In a first position, also referred to herein as a coupled or engaged position (shown in fig. 55F and 56F), knob 1550 mechanically engages an internal gear mechanism disposed within housing assembly 1460, as described more fully below. In a second position, also referred to herein as an uncoupled position or a disengaged position (shown in fig. 55E and 56E), knob 1550 is disposed outwardly or inwardly relative to the first position and mechanically decoupled from the gear mechanism. Disengagement of knob 1550 from engagement with the internal gear mechanism is preferably accomplished by pulling the control mechanism outwardly along axis a, offset from mounting flange 1404. Alternatively, a button or release, or a combination of button and knob 1550 rotation, or variations thereof, may be utilized to disengage the components, as will be understood by those skilled in the art, as described in the previous sections herein.

Referring now to fig. 57A through 57F, elements of spool assembly 1480 are shown in greater detail. Spool 1482 includes an annular groove 1483. The base of spool 1482 is defined by cylindrical wall 1481. In many embodiments, spool 1482 includes at least one lace access hole 1488, typically three or more holes 1488, and more preferably two holes 1488. The lace 23 can be removably secured to a spool 1482 having, for example, a spool screw 1484, with the spool screw 1484 passing through a spool screw hole 1498 (fig. 57C). While it is preferred that each screw 1484 secure a single lace end, a single screw secures multiple lace ends is also possible. Other means for releasably securing the lace to the spool are also contemplated, as described above. For example, lace 23 may be tied to spool 1482, as discussed above with reference to spool 1240 of tightening mechanism 1200. It is also possible to permanently secure the lace 23 to the spool by welding or the like, as will be appreciated by those skilled in the art. The releasable lacing allows for replacement of individual components of tightening mechanism 1400, rather than replacing the entire structure to which the lacing is tied.

The cylindrical wall 1481 typically has a diameter of less than about 0.75 inches, often no more than about 0.5 inches, and in one embodiment, the cylindrical wall 1481 has a diameter of about 0.4 inches.

The depth of the annular groove 1483 is typically less than 1/2 inches, often less than 3/8 inches, and, in some embodiments, no more than about 1/4 inches. In one embodiment, the depth is approximately 3/16 inches. The width of the annular groove 1483 at its opening is typically no greater than about 0.25 inches and, in one embodiment, no greater than about 0.13 inches.

Spool assembly 1480 preferably includes spool 1482 and main gear 1486. Master gear 1486 and spool 1482 are shown as being manufactured separately and then mechanically coupled together. Internal connecting teeth 1490 are configured to mesh in pairs with spool teeth 1491 to secure main gear 1486 to spool 1482. In an alternative embodiment, main gear 1486 and spool 1482 are manufactured from the same piece. Spool assembly 1480 may comprise metal. Alternatively, the spool assembly 1480 may comprise nylon or other rigid polymeric material, ceramic, or any combination thereof.

Spool screw holes 1498 are provided in the spool cavity 1495. The access aperture 1496 and the cover 1490 facilitate access to the aperture 1498. Likewise, lace 23 can be completely released from spool 1482 while shell 1450 is completely disassembled. Suitably, removal of knob assembly 1550 allows access to access aperture 1496. In some embodiments, knob 1560 is sized to allow access to the access hole without removing knob assembly 1550.

Knob assembly 1550 (fig. 58), preferably includes a cap 1572, a knob screw 1570, a knob 1560, and a pinion 1552. When engaged with knob 1560, cap 1572 loosely secures knob screw 1570 so that when the assembly is removed from housing assembly 1450, screw 1570 remains with knob assembly 1550. The cap 1572 may include indicia 1574 or provide a smooth surface. Advantageously, cap 1572 includes knob screw access holes 1576 so that knob screw 1570 can be engaged by a suitable tool without removing cap 1572 from knob 1560. Pinion gear 1552 is configured to fit within cavity 1564 of knob 1560.

As shown in FIG. 58, knob 1560 preferably includes a detent 1562 for engaging housing teeth 1494. The pawls 1562 and housing teeth 1494 are preferably configured to limit the direction of rotation of the knob 1560. Tightening mechanism 1400 may be manufactured for right or left handed operation, as discussed above with reference to other embodiments. The illustrated embodiment is configured for right-handed operation. Indicia are made on the components to ensure that the right-handed components are used with other right-handed components. Knob 1560 also includes a projection 1568, projection 1568 prevents the right hand operated knob assembly from being mounted on the left hand operated housing. The gripping surface 1569 of the knob 1560 may be manufactured separately or together with the knob 1560. It is preferred to use additional rubber molds, or other friction enhancing materials, to enhance the traction on the knob 1560.

Main gear 1486 includes gear teeth 1496 for meshing with pinion gear teeth 1556. The ratio of main gear to pinion gear is a factor in determining the amount of mechanical advantage achieved by tightening mechanism 1400. In some embodiments, this gear ratio is greater than about 1:1, often at least about 2:1, and in one embodiment at least about 3:1, and may be up to between about 4:1 or about 6: 1. In many embodiments of the present invention, main gear 1486 has an outer diameter of at least about 0.5 inches, often at least about 0.75 inches, and in one embodiment, at least about 1.0 inch. Main gear 1486 typically has an outer diameter of less than about 2 inches, preferably less than about 1.5 inches. In many embodiments, the outer diameter of the pinion gear 1552 is at least about 1/4 inches, often at least about 0.5 inches, and in one embodiment, at least about 3/8 inches. Pinion gear 1552 typically has an outer diameter of less than 0.1 inch, and preferably less than about 0.4 inch.

In many embodiments of the present invention, the outer diameter of knob 1560 is at least about 0.75 inches, often at least about 1.0 inch, and in one embodiment, at least about 1.5 inches. The outer diameter of knob 1560 is typically less than about 2.25 inches, and preferably less than about 1.75 inches.

The diameter of the lace used in cooperation with the cylindrical wall 1481 is preferably small enough so that the annular recess 1483 can accommodate at least about 14 inches of lace, preferably at least about 18 inches, and in some embodiments, at least about 22 inches, and in one embodiment, about 24 inches or more, excluding the connection end of the lace. At the full winding end of the winding cycle, the cylindrical stack of the wound tie is less than about 100% of the diameter of the knob 1560, and, preferably, less than about 75% of the diameter of the knob 1560. In one embodiment, the fully wound tie is less than at least about 65% of the diameter of knob 1560.

The combination of the gear ratio and the effective spool diameter and knob ratio achieves mechanical advantages. This combination of ratios results in a greater mechanical advantage than holding a compact package alone. In some embodiments of the invention, the combined ratio is greater than 1.5:1, in one embodiment at least about 2:1, in another embodiment about 3:1, and in yet another embodiment about 4: 1. The ratio is typically less than about 7: 1, often less than about 4.5: 1.

even when the spool is fully wound to its maximum, the maximum effective spool diameter, which is less than about 75% of the knob 1300 diameter, may still maintain sufficient leverage such that gearing or other leverage-enhancing structures are not necessary. As used herein, the term effective spool diameter refers to the outer diameter of the lace windings wound on the cylindrical wall 1252, as one skilled in the art will appreciate, the outer diameter of the lace windings will become larger as additional lace is wound on the cylindrical wall 1252.

In one embodiment, about 15 turns around cylindrical wall 1252 will accommodate about 24 inches of lace. Typically, at least about 10 turns, often at least about 12 turns, and preferably, at least about 15 turns of the lace wrapped around the cylindrical wall 1252 will still result in an effective spool diameter that is no more than about 65% or about 75% of the diameter of the knob 1301.

Laces having an outer diameter of less than about 0.060 inches are commonly used, and laces having an outer diameter of less than about 0.045 inches are often used. In certain preferred embodiments, a lace diameter of less than about 0.035 will be used.

Fig. 60A and 60B illustrate engaged and unengaged states of the housing assembly 1450 and the knob assembly 1550. Knob assembly 1550 is mechanically coupled to the housing assembly by shaft 1456 and knob screw 1570. Spring 1458 engages housing 1462 at one end and shaft cover 1457 at the other end. When knob assembly 1550 is engaged with shaft 1456, spring 1458 biases knob assembly 1550 in the engaged position such that pawls 1562 of knob 1560 engage housing teeth 1494 of housing cover 1490 and pinion teeth 1556 of pinion gear 1552 engage main gear teeth 1496 of main gear 1486.

In the engaged or disengaged position, shaft cover 1457 engages ledge 1466 to secure knob assembly 1550 in the disengaged position. Pulling knob 1560 back toward housing assembly 1450 disengages ledge 1466 and knob assembly 1550 reengages housing assembly 1450. In some embodiments, the pawls 1562 remain engaged with the housing teeth 1494 to prevent the knob 1560 from rotating in the opposite direction even in the disengaged position. However, pinion gears 1552 are disengaged from main gear 1486 in the disengaged position, thereby allowing free rotation of spool assembly 1480.

Although discussed in terms of footwear, the closure systems disclosed herein may provide effective and efficient closure options for a variety of different applications, including but not limited to ski boots, snow boots, skates, horse boots, hiking shoes, running shoes, athletic shoes, specialty shoes, and training shoes. These applications may include closure or attachment systems for backpacks and other articles for transportation and handling, waist and/or cuffs for belts, pants and jackets, collars and helmet ties, gloves, bindings for water and snow sports and other extreme sports, or any situation where a system to pull two objects together is advantageous.

Although the present invention has been disclosed in the context of certain preferred embodiments and examples, it will be understood by those skilled in the art that the present invention extends beyond the specifically disclosed embodiments to other alternative embodiments and/or uses of the invention and obvious modifications and equivalents thereof. In addition, while a number of variations of the invention have been shown and described in detail, other modifications, which are within the scope of this invention, will be readily apparent to those of skill in the art based upon this disclosure. It is also contemplated that specific features and aspects of the embodiments may be combined or sub-combined and still fall within the scope of the invention. Accordingly, it should be understood that various features and aspects of the present invention can be combined with or substituted for one another in order to achieve different modes of the invention. Therefore, it is intended that the scope of the present invention not be limited by the above-described embodiments, but should be determined only by a fair reading of the claims that follow.

Claims (49)

1. A lace tightening mechanism for a wearable article, the lace tightening mechanism comprising:

a tie strap;

a base member including a housing;

a spool comprising one or more annular grooves configured to receive the lace, the spool comprising spool teeth; and

a knob assembly configured to be progressively rotated in a forward rotational direction causing the lace to wrap around the spool, a bottom surface of the knob assembly including knob teeth that engage the spool teeth when the knob assembly is in an engaged state, the knob assembly having a disengaged state in which the knob teeth disengage from the spool teeth, thereby allowing free rotation of the spool;

wherein when the knob assembly is in the engaged state, engagement between the pawl and the teeth prevents rotation of the spool in the opposite direction, and wherein the pawl deflects axially as the knob assembly is progressively rotated in the forward rotational direction.

2. The lace tightening mechanism of claim 1 wherein rotation of the knob assembly causes the knob teeth to disengage from the spool teeth.

3. The lace tightening mechanism of claim 1 wherein disengagement of the knob teeth from the spool teeth is accomplished by pulling the knob assembly away from the base member.

4. The tie-tightening mechanism of claim 1, further comprising an axial pin attached to the base member.

5. The tie-tightening mechanism of claim 4, wherein a central axial opening extends through the spool and includes an interior sidewall, and wherein the interior sidewall of the central axial opening of the spool slidingly engages the axial pin to stabilize the spool.

6. The tie-tightening mechanism of claim 4 wherein the axial pin is made of a metallic material.

7. The tie-tightening mechanism of claim 4, wherein the axial pin is removably coupled to the base member.

8. The tie-tightening mechanism of claim 4, wherein the axial pin includes an upper sleeve adapted to slidably engage an inner wall of the axial opening of the knob assembly.

9. The lace tightening mechanism of claim 1 wherein when the knob assembly is in the disengaged state, the spool rotates in an opposite direction in response to traction of the lace and the spool does not rotate in an opposite direction in response to rotation of the knob assembly.

10. The tie-tightening mechanism of claim 1 wherein the spool includes two sets of three retaining holes adapted to receive tie ends for removably securing the tie to the spool.

11. The tie tightening mechanism of claim 10, wherein the tie extends through the retaining hole such that a portion of the tie forms a loop and the end of the tie passes through the loop, tension being applied to the tie to tighten the knot thereby created.

12. The tie-tightening mechanism of claim 1 wherein the spool rotates about an axis that is coaxial with the axis of rotation of the knob assembly.

13. The tie-tightening mechanism of claim 1 wherein the knob assembly includes the pawl.

14. The tie-tightening mechanism of claim 1, wherein the housing includes the teeth.

15. A footwear component comprising a lacing system, comprising the tightening mechanism of any one of claims 1 to 14.

16. A cable tie-down mechanism for a wearable article, comprising:

a housing including a housing bore;

a spool configured to hold a cable, the spool including a spool bore;

a spring coupling the spool to the housing;

a rigid pin extending between the housing hole and the spool hole, the rigid pin holding the spool and the housing relative to each other so that the spring is held in a biased position, the rigid pin further configured to be removed from the housing hole and the spool hole to allow movement between the spool and the housing to release tension from the biased spring.

17. The cable tie-down mechanism of claim 16, wherein the spool further includes a pair of cable entry holes.

18. The cable tie-down mechanism of claim 17, wherein the spool hole is commensurate with at least one of the cable entry holes.

19. The cable tie-down mechanism of claim 16 wherein the housing bore extends through an upper surface of the housing, the housing including a releasable base opposite the upper surface of the housing that can be selectively attached to the housing to substantially cover an interior cavity of the housing.

20. The cable tie mechanism of claim 19 wherein the spring is disposed within the interior cavity of the housing between the spool and the base of the housing.

21. A footwear member including the cable tie mechanism of any one of claims 16 to 20.

22. A tightening mechanism for a lacing system on a wearable article, the tightening mechanism comprising:

a tie strap;

a housing;

a spool assembly comprising a spool and a main gear, wherein the main gear and the spool are manufactured separately and then mechanically connected together, wherein the main gear comprises main gear teeth, wherein the lace is removably secured to the spool;

a rotatable knob assembly including a knob and a pinion, wherein the spool assembly is offset from the knob assembly on an axis, wherein the pinion includes pinion teeth, the knob assembly having an engaged state in which the pinion teeth engage the primary gear teeth such that the spool rotates by interaction with the pinion, the knob assembly having a disengaged state in which the pinion is disengaged from the primary gear, thereby allowing free rotation of the spool assembly.

23. A fastening mechanism according to claim 22 wherein the spool comprises spool teeth and the main gear comprises internal connecting teeth configured to mesh in pairs with the spool teeth to secure the main gear to the spool.

24. The tying mechanism of claim 22, wherein the spool assembly comprises metal.

25. The tie-down mechanism of claim 22, wherein the knob assembly is slidably movable relative to the housing along an axis between two positions.

26. A tie mechanism as claimed in claim 22 wherein the pinion gear and main gear can be disengaged by rotation of the knob.

27. The tightening mechanism of claim 22, wherein the spool comprises three or more holes, wherein the lace is tied on the spool, wherein the lace passes into the three or more holes such that a portion of the lace forms a loop, and wherein an end of the lace passes through the loop.

28. The tie-down mechanism of claim 22 wherein the housing includes a mounting flange, wherein the housing includes two side strap inlets disposed on the mounting flange on opposite sides of the housing.

29. The tightening mechanism of claim 22, wherein when the knob is in the engaged state, the tooth/pawl engagement prevents the knob and the spool from rotating in a rearward direction.

30. The tie-down mechanism of claim 29, wherein said pawl remains engaged with said teeth to prevent rotation of said knob in said opposite direction when in said disengaged state.

31. The tightening mechanism of claim 22, wherein the strap has an outer diameter of less than about 0.060 inches.

32. The tightening mechanism of claim 22, wherein the knob assembly includes additional rubber molding, or other friction enhancing material, to enhance traction.

33. The tie-down mechanism of claim 22, wherein the knob assembly includes a cover and a knob screw, wherein the cover includes a knob screw entry hole such that the knob screw can be engaged without removing the cover from the knob.

34. The tie-down mechanism of claim 33, wherein the knob assembly is mechanically coupled to the housing by a shaft and the knob screw.

35. The tightening mechanism of claim 22, wherein the knob includes a cavity, and wherein the pinion is mounted in the cavity of the knob.

36. A fastening mechanism according to claim 22, wherein the ratio of the main gear to the pinion gear is at least about 2: 1.

37. The tie-down mechanism of claim 22, wherein the effective spool diameter is less than 75% of the diameter of the knob.

38. A footwear component comprising a lacing system, comprising the tightening mechanism of any one of claims 22 to 37.

39. A tightening mechanism for a lacing system on a wearable article, the tightening mechanism comprising:

a tie strap;

a base member configured to be secured to the wearable article independent of a remainder of the fastening mechanism, the base member including an internal cavity and one or more strap holes therethrough;

a housing configured to fit within the interior cavity of the base member, wherein the housing comprises a housing interior cavity and one or more strap entry holes;

a rotatable spool disposed in the housing interior cavity;

a knob coupled to the spool such that rotation of the knob causes the spool to rotate;

wherein the lace extends through the one or more lace apertures of the base member, through the one or more lace entry apertures of the housing, and into the housing lumen, wherein the lace is coupled to the spool.

40. The tie-down mechanism of claim 39, wherein the base member comprises a mounting flange for mounting the base member to the wearable article.

41. The tightening mechanism of claim 40, wherein the base member includes an upper portion disposed on the mounting flange, wherein the one or more lacing holes extend through the upper portion.

42. The tightening mechanism of claim 41, wherein the base member includes a lower portion disposed below the mounting flange.

43. The tightening mechanism of claim 40, wherein the base member includes a lower portion disposed below the mounting flange, wherein the one or more lacing holes extend through the lower portion.

44. The tightening mechanism of claim 43, wherein the base member includes an upper portion disposed on the mounting flange.

45. A footwear component, comprising:

the tightening mechanism of claim 43;

one or more lace guides disposed within a structure of footwear, wherein the one or more lace guides are configured to guide the lace to the one or more lace apertures of the base member.

46. The footwear member of claim 45, wherein the lace is completely concealed beneath a surface of the footwear member.

47. The tightening mechanism of claim 39, wherein the base member includes two lacing holes.

48. The tightening mechanism of claim 47, wherein the two lacing holes are on opposite sides of the base member.

49. A footwear member comprising the tightening mechanism of any one of claims 39 to 48.