Footwear Having Sensor System

Abstract

A sensor system is adapted for use with an article of footwear and includes an insert member including a first layer and a second layer, a port connected to the insert and configured for communication with an electronic module, a plurality of force and/or compression sensors on the insert member, and a plurality of leads connecting the sensors to the port.

What is claimed is: 
     
         1 . A sensor system comprising:
 an insert member configured to be inserted into a foot-receiving chamber of an article of footwear, the insert member comprising a first layer and a second layer; and   a sensor comprising:
 a first contact located on the first layer, the first contact comprising a plurality of first segments each being elongated along an axis between first and second opposed ends, wherein each first segment has a width defined perpendicular to the axis, and wherein each first segment tapers from the first end to the second end such that the width is greater at the first end and narrower at the second end, and wherein the first segments are arranged in an alternating arrangement, such that the first end of each of the first segments is aligned with the second end of any adjacent first segment and the second end of each of the first segments is aligned with the first end of any adjacent first segment; and 
 a second contact located on the second layer, the second contact comprising a plurality of second segments each being elongated along an axis between first and second opposed ends, wherein each second segment has a width defined perpendicular to the axis, and wherein each second segment tapers from the first end to the second end such that the width is greater at the first end and narrower at the second end, and wherein the second segments are arranged in an alternating arrangement, such that the first end of each of the second segments is aligned with the second end of any adjacent second segment and the second end of each of the second segments is aligned with the first end of any adjacent second segment, 
 wherein the first contact and the second contact are arranged in a superimposed manner, such that each of the first segments is in confronting relation to one of the second segments, and the first ends of the first segments are aligned with the first ends of the second segments in confronting relation thereto, and 
 wherein the sensor is configured to change in resistance when pressure is applied to the sensor to cause increased engagement between the first and second contacts. 
   
     
     
         2 . The system of  claim 1 , wherein at least some of the first segments and at least some of the second segments have generally isosceles triangular shapes. 
     
     
         3 . The system of  claim 1 , wherein each of the first segments has at least one tapering edge extending from the first end to the second end, with each tapering edge having a trough and a projection along a length thereof, and wherein the tapering edges of adjacent first segments are arranged such that the trough of each tapering edge is generally aligned with the projection of the tapering edge of the adjacent first segment. 
     
     
         4 . The system of  claim 1 , further comprising a spacer layer located between the first and second layers, wherein the spacer layer has a hole generally aligned with the first and second contacts and configured to permit engagement of the first and second contacts through the spacer layer. 
     
     
         5 . The system of  claim 1 , further comprising a plurality of additional sensors having structures substantially identical to the sensor. 
     
     
         6 . The system of  claim 5 , wherein the sensor is located in a first phalangeal area of the insert, and the additional sensors comprise a second sensor located in a first metatarsal area of the insert, a third sensor located in a fifth metatarsal area of the insert, and a fourth sensor located in a heel area of the insert. 
     
     
         7 . The system of  claim 1 , further comprising a spacer layer located between the first and second layers, wherein the spacer layer has a hole generally aligned with the first and second contacts and configured to permit engagement of the first and second contacts through the spacer layer. 
     
     
         8 . The system of  claim 1 , further comprising a dielectric material connected to the second layer and at least partially covering a top surface of the second contact, wherein the dielectric material reduces a total potential surface area for engagement between the first and second contacts. 
     
     
         9 . The system of  claim 8 , wherein the dielectric material covers peripheral portions of each of the second segments extending from the second end toward the first end over at least a portion of a length of each second segment. 
     
     
         10 . The system of  claim 9 , wherein the dielectric material is arranged in an alternating wishbone pattern comprising a plurality of wishbone structures each having a converging end located at the second end of one of the second segments and legs extending from the converging end along the peripheral portions of the second segments and further extending to the converging ends of adjacent wishbone structures. 
     
     
         11 . The system of  claim 1 , further comprising:
 a port connected to the insert and configured for communication with an electronic module; and   a plurality of leads located on the insert and connecting the first and second contacts to the port.   
     
     
         12 . The system of  claim 1 , further comprising:
 a spacer layer located between the first and second layers, wherein the spacer layer has a hole generally aligned with the first and second contacts and configured to permit engagement of the first and second contacts through the spacer layer;   a port connected to the insert and configured for communication with an electronic module;   a plurality of additional sensors having structures substantially identical to the sensor; and   a plurality of leads located on the insert and connecting the first and second contacts of each sensor to the port,   wherein the sensor is located in a first phalangeal area of the insert, and the additional sensors comprise a second sensor located in a first metatarsal area of the insert, a third sensor located in a fifth metatarsal area of the insert, and a fourth sensor located in a heel area of the insert.   
     
     
         13 . A sensor system comprising:
 an insert member configured to be inserted into a foot-receiving chamber of an article of footwear, the insert member comprising a first layer and a second layer; and   a sensor comprising:
 a first contact located on the first layer; and 
 a second contact located on the second layer, wherein the first contact and the second contact are arranged in a superimposed manner, such that the a bottom surface of the first contact confronts a top surface of the second contact, and wherein the sensor is configured to change in resistance when pressure is applied to the sensor to cause increased engagement between the first and second contacts; and 
   a dielectric material connected to the second layer and at least partially covering the top surface of the second contact, wherein the dielectric material reduces a total potential surface area for engagement between the first and second contacts.   
     
     
         14 . The system of  claim 13 , further comprising a spacer layer located between the first and second layers, wherein the spacer layer has a hole generally aligned with the first and second contacts and configured to permit engagement of the first and second contacts through the spacer layer. 
     
     
         15 . The system of  claim 13 , wherein the dielectric material is arranged in an alternating wishbone pattern. 
     
     
         16 . The system of  claim 13 , wherein the first contact comprises a plurality of first segments separated from each other by spaces, and the second contact comprises a plurality of second segments separated from each other by spaces, such that each of the first segments is in confronting relation to one of the second segments and the confronting first and second segments are configured to engage each other when pressure is applied to the sensor, and wherein the dielectric material covers a portion of each of the second segments. 
     
     
         17 . The system of  claim 16 , wherein:
 the first segments are each elongated along an axis between first and second opposed ends, wherein each first segment has a width defined perpendicular to the axis, wherein each first segment tapers from the first end to the second end such that the width is greater at the first end and narrower at the second end, and wherein the first segments are arranged in an alternating arrangement, such that the first end of each of the first segments is aligned with the second end of any adjacent first segment and the second end of each of the first segments is aligned with the first end of any adjacent first segment;   the second segments are each elongated along an axis between first and second opposed ends, wherein each second segment has a width defined perpendicular to the axis, and wherein each second segment tapers from the first end to the second end such that the width is greater at the first end and narrower at the second end, and wherein the second segments are arranged in an alternating arrangement, such that the first end of each of the second segments is aligned with the second end of any adjacent second segment and the second end of each of the second segments is aligned with the first end of any adjacent second segment; and   the first contact and the second contact are arranged such that the first ends of the first segments are aligned with the first ends of the second segments in confronting relation thereto.   
     
     
         18 . The system of  claim 17 , wherein the dielectric material covers peripheral portions of each of the second segments extending from the second end toward the first end over at least a portion of a length of each second segment. 
     
     
         19 . The system of  claim 18 , wherein the dielectric material is arranged in an alternating wishbone pattern comprising a plurality of wishbone structures each having a converging end located at the second end of one of the second segments and legs extending from the converging end along the peripheral portions of the second segments and further extending to the converging ends of adjacent wishbone structures. 
     
     
         20 . The system of  claim 13 , further comprising:
 a port connected to the insert and configured for communication with an electronic module; and   a plurality of leads located on the insert and connecting the first and second contacts to the port.   
     
     
         21 . The system of  claim 13 , further comprising a plurality of additional sensors having structures substantially identical to the sensor. 
     
     
         22 . The system of  claim 13 , further comprising:
 a spacer layer located between the first and second layers, wherein the spacer layer has a hole generally aligned with the first and second contacts and configured to permit engagement of the first and second contacts through the spacer layer;   a port connected to the insert and configured for communication with an electronic module;   a plurality of additional sensors having structures substantially identical to the sensor; and   a plurality of leads located on the insert and connecting the first and second contacts of each sensor to the port,   wherein the sensor is located in a first phalangeal area of the insert, and the additional sensors comprise a second sensor located in a first metatarsal area of the insert, a third sensor located in a fifth metatarsal area of the insert, and a fourth sensor located in a heel area of the insert.   
     
     
         23 . A sensor system comprising:
 an insert member configured to be inserted into a foot-receiving chamber of an article of footwear, the insert member comprising a first layer, a second layer, and a spacer layer located between the first and second layers; and   a plurality of sensors connected to the insert, each sensor comprising:
 a first contact located on the first layer, the first contact comprising a plurality of first segments each being elongated along an axis between first and second opposed ends, wherein each first segment has a width defined perpendicular to the axis, and wherein each first segment tapers from the first end to the second end such that the width is greater at the first end and narrower at the second end, and wherein the first segments are arranged in an alternating arrangement, such that the first end of each of the first segments is aligned with the second end of any adjacent first segment and the second end of each of the first segments is aligned with the first end of any adjacent first segment; 
 a second contact located on the second layer, the second contact comprising a plurality of second segments each being elongated along an axis between first and second opposed ends, wherein each second segment has a width defined perpendicular to the axis, and wherein each second segment tapers from the first end to the second end such that the width is greater at the first end and narrower at the second end, and wherein the second segments are arranged in an alternating arrangement, such that the first end of each of the second segments is aligned with the second end of any adjacent second segment and the second end of each of the second segments is aligned with the first end of any adjacent second segment, 
 wherein the first contact and the second contact are arranged in a superimposed manner, such that each of the first segments is in confronting relation to one of the second segments, and the first ends of the first segments are aligned with the first ends of the second segments in confronting relation thereto, and 
 wherein the sensor is configured to change in resistance when pressure is applied to the sensor to cause increased engagement between the first and second contacts; and 
   a dielectric material connected to the second layer and at least partially covering the top surface of the second contact of each sensor, wherein the dielectric material reduces a total potential surface area for engagement between the first and second contacts, wherein the dielectric material on each sensor is arranged in an alternating wishbone pattern comprising a plurality of wishbone structures each having a converging end located at the second end of one of the second segments and legs extending from the converging end along the peripheral portions of the second segments and further extending to the converging ends of adjacent wishbone structures, and   wherein the spacer layer comprises holes aligned with the sensors and configured to permit engagement of the first and second contacts of each sensor through the spacer layer.   
     
     
         24 . A method comprising:
 printing a first sensor contact on a polymeric film member, wherein the first sensor contact comprises a plurality of first segments each being elongated along an axis between first and second opposed ends, wherein each first segment has a width defined perpendicular to the axis, and wherein each first segment tapers from the first end to the second end such that the width is greater at the first end and narrower at the second end, and wherein the first segments are arranged in an alternating arrangement, such that the first end of each of the first segments is aligned with the second end of any adjacent first segment and the second end of each of the first segments is aligned with the first end of any adjacent first segment,   wherein the printing is performed in a print direction that is parallel to the axis of the first sensor contact.   
     
     
         25 . The method of  claim 24 , further comprising printing a dielectric material on the film member such that the dielectric material at least partially covers a top surface of the first sensor contact. 
     
     
         26 . The method of  claim 25 , wherein the dielectric material is arranged in an alternating wishbone pattern. 
     
     
         27 . The method of  claim 25 , wherein the dielectric material covers peripheral portions of each of the first segments extending from the second end toward the first end over at least a portion of a length of each first segment. 
     
     
         28 . The method of  claim 27 , wherein the dielectric material is arranged in an alternating wishbone pattern comprising a plurality of wishbone structures each having a converging end located at the second end of one of the first segments and legs extending from the converging end along the peripheral portions of the first segments and further extending to the converging ends of adjacent wishbone structures. 
     
     
         29 . The method of  claim 24 , further comprising:
 printing a second sensor contact on the polymeric film member at a location remote from the first sensor contact, wherein the second sensor contact comprises a plurality of second segments each being elongated along a second axis between third and fourth opposed ends, wherein each second segment has a second width defined perpendicular to the second axis, and wherein each second segment tapers from the third end to the fourth end such that the width is greater at the third end and narrower at the fourth end, and wherein the second segments are arranged in an alternating arrangement, such that the third end of each of the second segments is aligned with the fourth end of any adjacent second segment and the fourth end of each of the second segments is aligned with the third end of any adjacent second segment,   wherein the second axis is substantially parallel to the axis of the first sensor contact.