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 pressure 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;   a port connected to the insert and configured for communication with an electronic module;   a pathway providing electrical communication between the first layer and the second layer;   a plurality of sensors formed on the insert member, each sensor comprising a first contact located on the first layer and a second contact located on the second layer, the second contact being generally aligned with the first contact, wherein the sensors are each configured such that pressure on the insert causes increased engagement between the first and second contacts to change a resistance of the sensor;   a plurality of leads located on the first layer and the second layer, the leads connecting the first contacts, the second contacts, the pathway, and the port;   a first resistor located on the first layer and connected to at least one of leads; and   a second resistor located on the second layer and connected at least one of the leads,   wherein the port, the pathway, the sensors, the leads, and the first and second resistors form a circuit on the insert member, the circuit configured to have a voltage applied between a first terminal and a ground located at the port, and wherein the first and second resistors are arranged in parallel between the first terminal and the ground.   
     
     
         2 . The sensor system of  claim 1 , further comprising a spacer layer located between the first and second layers, the spacer layer having holes aligned with the sensors to permit engagement of the first and second contacts of each sensor through the spacer layer. 
     
     
         3 . The sensor system of  claim 2 , the spacer layer having an additional hole therein aligned with the pathway to permit electrical communication between the first and second layers through the pathway. 
     
     
         4 . The sensor system of  claim 1 , wherein the first resistor and the second resistor each comprise:
 an inner section connected to a first lead,   an outer section connected to a second lead, the outer section at least partially surrounding the inner section and being spaced from the inner section, and   a bridge extending between the inner section and the outer section and partially overlapping both the inner section and the outer section, wherein the resistor is configured such that an electronic signal can pass between the first lead and the second lead through the inner section, the bridge, and the outer section.   
     
     
         5 . The sensor system of  claim 4 , wherein the outer sections of the first and second resistors each comprise a first semi-annular ring that at least partially surrounds the inner section, and the bridges of the first and second resistors each comprise a second semi-annular ring with an inner semi-circular edge and an outer semi-circular edge, wherein the inner edge of the bridge overlaps the inner section and the outer edge of the bridge overlaps the outer section. 
     
     
         6 . The sensor system of  claim 5 , wherein the inner and outer sections of the first and second resistors are formed of a silver material, and the bridges of the first and second resistors are formed of a carbon material. 
     
     
         7 . The sensor system of  claim 6 , wherein the first and second contacts of each of the sensors are formed of the carbon material, and the plurality of leads are all formed of the silver material. 
     
     
         8 . The sensor system of  claim 4 , wherein the first lead of the first resistor and the first lead of the second resistor are each connected to the pathway. 
     
     
         9 . The sensor system of  claim 1 , wherein the pathway comprises a first conductive portion on the first layer and a second conductive portion on the second layer, wherein the first and second conductive portions are in continuous engagement with each other to provide electrical communication between the first and second layers, and wherein the first resistor is directly connected to the first conductive portion by one of the leads and the second resistor is directly connected to the second conductive portion by another one of the leads. 
     
     
         10 . The sensor system of  claim 1 , wherein the circuit further comprises a measurement terminal at the port electrically connected between the first and second resistors combined and each of the sensors and configured for measuring a voltage between the measurement terminal and the ground, and wherein each of sensors forms a voltage divider with the first and second resistors combined, such that a voltage between the first terminal and the ground is divided between each sensor and the first and second resistors combined, and the voltage between the measurement terminal and the ground changes as the resistance of each sensor changes. 
     
     
         11 . A sensor system comprising:
 an insert member configured to be inserted into a foot-receiving chamber of an article of footwear;   a port connected to the insert and configured for communication with an electronic module;   a plurality of sensors formed on the insert member, each sensor configured for detecting pressure applied to the sensor;   a plurality of leads located on the insert and connecting the sensors to the port; and   a resistor connected to the sensors and the port by the leads, the resistor comprising:
 an inner section connected to a first lead, 
 an outer section connected to a second lead, the outer section substantially surrounding the inner section and being spaced from the inner section, and 
 a bridge extending between the inner section and the outer section and partially overlapping both the inner section and the outer section, wherein the resistor is configured such that an electronic signal can pass between the first lead and the second lead through the inner section, the bridge, and the outer section. 
   
     
     
         12 . The sensor system of  claim 11 , wherein the inner and outer sections are formed of a silver material, and the bridge is formed of a carbon material. 
     
     
         13 . The sensor system of  claim 11 , wherein the outer section comprises a first semi-annular ring that at least partially surrounds the inner section, and the bridge comprises a second semi-annular ring with an inner semi-circular edge and an outer semi-circular edge, wherein the inner edge of the bridge overlaps the inner section and the outer edge of the bridge overlaps the outer section. 
     
     
         14 . The sensor system of  claim 13 , wherein the inner and outer sections are formed of a silver material, and the bridge is formed of a carbon material. 
     
     
         15 . The sensor system of  claim 11 , wherein the insert comprises a first layer and a second layer, wherein the sensors each comprise a first contact on the first layer and a second contact on the second layer, each sensor configured to detect pressure by engagement between the first and second contacts, and wherein the resistor is located on the first layer and positioned between the first contacts of the sensors and the port, further comprising:
 a second resistor located on the second layer and connected to the sensors and the port by the leads, the second resistor comprising:
 a second inner section connected to a third lead, 
 a second outer section connected to a fourth lead, the second outer section substantially surrounding the second inner section and being spaced from the second inner section, and 
 a second bridge extending between the second inner section and the second outer section and partially overlapping both the second inner section and the second outer section, wherein the second resistor is configured such that an electronic signal can pass between the third lead and the fourth lead through the second inner section, the second bridge, and the second outer section. 
   
     
     
         16 . The sensor system of  claim 15 , wherein the port, the sensors, the leads, the resistor, and the second resistor form a circuit on the insert member, the circuit configured to have a voltage applied between a first terminal and a ground located at the port, and wherein the resistor and the second resistor are arranged in parallel between the first terminal and the ground. 
     
     
         17 . The sensor system of  claim 16 , wherein the circuit further comprises a measurement terminal at the port electrically connected between the first and second resistors combined and each of the sensors and configured for measuring a voltage between the measurement terminal and the ground, and wherein each of sensors forms a voltage divider with the resistor and the second resistor combined, such that a voltage between the first terminal and the ground is divided between each sensor and the resistor and the second resistor combined, and the voltage between the measurement terminal and the ground changes as the resistance of each sensor changes. 
     
     
         18 . 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;   a port connected to the insert and configured for communication with an electronic module;   a pathway providing electrical communication between the first layer and the second layer, the spacer layer having a hole therein to permit electrical communication between the first and second layers through the pathway;   a plurality of sensors formed on the insert member, each sensor comprising a first contact located on the first layer and a second contact located on the second layer, the second contact being generally aligned with the first contact, wherein the sensors are each configured such that pressure on the insert causes increased engagement between the first and second contacts to change a resistance of the sensor, wherein the first and second contacts comprise a carbon material;   a plurality of leads located on the first layer and the second layer, the leads connecting the first contacts to the pathway, connecting the second contacts to the port, and connecting the port to the pathway, wherein the leads comprise a silver material;   a first resistor located on the first layer and connected to at least two of leads; and   a second resistor located on the second layer and connected at least two of the leads, wherein the first resistor and the second resistor each comprise:
 an inner section connected to first lead and comprising the silver material; 
 an outer section connected to a second lead and comprising the silver material, the outer section substantially surrounding the inner section and being spaced from the inner section, and 
 a bridge extending between the inner section and the outer section and partially overlapping both the inner section and the outer section, the bridge comprising the carbon material, wherein the first and second resistors are configured such that an electronic signal can pass between the first lead and the second lead through the inner section, the bridge, and the outer section; and 
   wherein the port, the pathway, the sensors, the leads, and the first and second resistors form a circuit on the insert member, the circuit configured to have a voltage applied between a first terminal and a ground located at the port, and wherein the first and second resistors are arranged in parallel between the first terminal and the ground.   
     
     
         19 . The sensor system of  claim 18 , wherein the outer sections of the first and second resistors each comprise a first semi-annular ring that at least partially surrounds the inner section, and the bridges of the first and second resistors each comprise a second semi-annular ring with an inner semi-circular edge and an outer semi-circular edge, wherein the inner edge of the bridge overlaps the inner section and the outer edge of the bridge overlaps the outer section. 
     
     
         20 . The sensor system of  claim 19 , wherein the first and second semi-annular rings have ends defining a gap therebetween, and the first lead extends through the gap to pass away from the resistor without contacting the outer section or the bridge. 
     
     
         21 . The sensor system of  claim 18 , wherein the pathway comprises a first conductive portion on the first layer and a second conductive portion on the second layer, wherein the first and second conductive portions are in continuous engagement with each other to provide electrical communication between the first and second layers, and wherein the first lead of the first sensor is directly connected to the first conductive portion and the first lead of the second resistor is directly connected to the second conductive portion. 
     
     
         22 . The sensor system of  claim 18 , wherein the first resistor and the second resistor are arranged so that an electronic signal from any of the sensors to the port must pass through at least one of the first and second resistors. 
     
     
         23 . The sensor system of  claim 18 , wherein the circuit further comprises a measurement terminal at the port electrically connected between the first and second resistors combined and each of the sensors and configured for measuring a voltage between the measurement terminal and the ground, and wherein each of sensors forms a voltage divider with the first and second resistors combined, such that a voltage between the first terminal and the ground is divided between each sensor and the first and second resistors combined, and the voltage between the measurement terminal and the ground changes as the resistance of each sensor changes. 
     
     
         24 . 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;   a port connected to the insert and configured for communication with an electronic module;   a pathway providing electrical communication between the first layer and the second layer, wherein the spacer layer includes a hole located around the pathway to permit the electrical communication between the first and second layers through the pathway;   a plurality of sensors formed on the insert member, each sensor comprising a first contact located on the first layer and a second contact located on the second layer, the second contact being generally aligned with the first contact, wherein the sensors are each configured such that pressure on the insert causes increased engagement between the first and second contacts to change resistance of the sensor; and   a plurality of leads located on the first layer and the second layer, the leads connecting the first contacts to the pathway, connecting the second contacts to the port, and connecting the port to the pathway.   
     
     
         25 . The system of  claim 24 , wherein the pathway comprises a first conductive portion on the first layer and a second conductive portion on the second layer, wherein the first and second conductive portions are in continuous engagement with each other through the hole to provide electrical communication between the first and second layers. 
     
     
         26 . The system of  claim 25 , further comprising:
 a first resistor located on the first layer and connected to the first conductive portion by one or more leads; and   a second resistor located on the second layer and connected to the second conductive portion by one or more additional leads,   wherein the port, the pathway, the sensors, the leads, and the first and second resistors form a circuit on the insert member, the circuit configured to have a voltage applied between a first terminal and a ground located at the port, and wherein the first and second resistors are arranged in parallel between the first terminal and the ground.   
     
     
         27 . The system of  claim 24 , wherein the pathway further comprises a substantially annular stiffener positioned around the pathway on at least one of the first and second layers, wherein the stiffener has decreased flexibility compared to the pathway. 
     
     
         28 . The system of  claim 27 , wherein the pathway comprises a first conductive portion on the first layer and a second conductive portion on the second layer, wherein the first and second conductive portions are in continuous engagement with each other through the hole to provide electrical communication between the first and second layers, and wherein the stiffener is located on the first layer and positioned around the first conductive portion, and the pathway further comprises a second substantially annular stiffener located on the second layer and positioned around the second conductive portion, wherein the second stiffener has decreased flexibility compared to the pathway. 
     
     
         29 . The system of  claim 28 , wherein the hole in the spacer layer is larger than the first and second stiffeners, and wherein the first and second layers deflect toward each other through the hole to be in continuous engagement with each other, such that the first and second stiffeners define a substantially annular transition region on each of the first and second layers, wherein the first and second layers deflect toward each other at the transition region and a majority of the first and second conductive portions are in engagement with each other inside an area bounded by the transition region. 
     
     
         30 . The system of  claim 29 , wherein the first and second conductive portions are in continuous engagement with each other through the hole over substantially an entirety of the area bounded by the transition region. 
     
     
         31 . The system of  claim 29 , wherein the transition region on each of the first and second layers is defined by an outer annular break line and an inner annular break line, with the transition region between the outer and inner break lines and with the first and second conductive portions within the inner break line, wherein the first and second layers are generally horizontal outside the outer break line and within the inner break line, and the first and second layers slope toward each other at the transition regions to create engagement between the first and second conductive portions. 
     
     
         32 . The system of  claim 28 , wherein the first and second conductive portions each have a gap extending therethrough and dividing the first and second conductive portions into separate first and second sections, and wherein the gaps of the first and second conductive portions are aligned such that the first section of the first conductive portion engages the first section of the second conductive portion and the second section of the first conductive portion engages the second section of the second conductive portion, with no direct engagement between the first sections and the second sections. 
     
     
         33 . The system of  claim 32 , wherein the first and second conductive portions are circular and the gaps extend across a diameter of each of the first and second conductive portions, such that the first and second sections of each of the first and second conductive portions is semi-circular in shape. 
     
     
         34 . 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;   a port connected to the insert and configured for communication with an electronic module;   a pathway providing electrical communication between the first layer and the second layer, wherein the spacer layer includes a hole located around the pathway to permit the electrical communication between the first and second layers through the pathway, the pathway further comprising a substantially annular stiffener positioned around the pathway on at least one of the first and second layers, wherein the stiffener has decreased flexibility compared to the pathway;   a plurality of sensors formed on the insert member, each sensor comprising a first contact located on the first layer and a second contact located on the second layer, the sensor configured to sense pressure on the sensor through engagement between the first and second contacts; and   a plurality of leads located on the first layer and the second layer, the leads connecting the first contacts and the second contacts to the port and to the pathway.   
     
     
         35 . The system of  claim 34 , wherein the pathway comprises a first conductive portion on the first layer and a second conductive portion on the second layer, wherein the first and second conductive portions are in continuous engagement with each other through the hole to provide electrical communication between the first and second layers, and wherein the stiffener is located on the first layer and positioned around the first conductive portion, and the pathway further comprises a second substantially annular stiffener located on the second layer and positioned around the second conductive portion, wherein the second stiffener has decreased flexibility compared to the pathway. 
     
     
         36 . The system of  claim 35 , wherein the hole in the spacer layer is larger than the first and second stiffeners, and wherein the first and second layers deflect toward each other through the hole to be in continuous engagement with each other, such that the first and second stiffeners define a substantially annular transition region on each of the first and second layers, wherein the first and second layers deflect toward each other at the transition region and a majority of the first and second conductive portions are in engagement with each other inside an area bounded by the transition region. 
     
     
         37 . The system of  claim 36 , wherein the transition region on each of the first and second layers is defined by an outer annular break line and an inner annular break line, with the transition region between the outer and inner break lines and with the first and second conductive portions within the inner break line, wherein the first and second layers are generally horizontal outside the outer break line and within the inner break line, and the first and second layers slope toward each other at the transition regions to create engagement between the first and second conductive portions. 
     
     
         38 . The system of  claim 35 , wherein the first and second conductive portions each have a gap extending therethrough and dividing the first and second conductive portions into separate first and second sections, and wherein the gaps of the first and second conductive portions are aligned such that the first section of the first conductive portion engages the first section of the second conductive portion and the second section of the first conductive portion engages the second section of the second conductive portion, with no direct engagement between the first sections and the second sections. 
     
     
         39 . The system of  claim 38 , wherein the first and second conductive portions are circular and the gaps extend across a diameter of each of the first and second conductive portions, such that the first and second sections of each of the first and second conductive portions is semi-circular in shape. 
     
     
         40 . The system of  claim 35 , further comprising:
 a first resistor located on the first layer and connected to the first conductive portion by one or more leads; and   a second resistor located on the second layer and connected to the second conductive portion by one or more additional leads,   wherein the port, the pathway, the sensors, the leads, and the first and second resistors form a circuit on the insert member, the circuit configured to have a voltage applied between a first terminal and a ground located at the port, and wherein the first and second resistors are arranged in parallel between the first terminal and the ground.   
     
     
         41 . 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;   a port connected to the insert and configured for communication with an electronic module;   a plurality of sensors formed on the insert member, each sensor comprising a first contact located on the first layer and a second contact located on the second layer, the sensor configured to sense pressure on the sensor through engagement between the first and second contacts, wherein the plurality of sensors comprises a first metatarsophalangeal sensor located in a position configured to be directly beneath a first metatarsophalangeal joint of a user and a fourth metatarsophalangeal sensor located in a position configured to be directly beneath a fourth metatarsophalangeal joint of the user;   a pathway providing electrical communication between the first layer and the second layer, wherein the spacer layer includes a hole located around the pathway to permit the electrical communication between the first and second layers through the pathway, the pathway being located in a position configured to be beneath at least one of a second metatarsophalangeal joint and a third metatarsophalangeal joint of the user, the pathway further comprising a first conductive portion on the first layer and a second conductive portion on the second layer, wherein the first and second conductive portions are in continuous engagement with each other through the hole to provide electrical communication between the first and second layers, with the first and second conductive portions each having a gap extending therethrough and dividing the first and second conductive portions into separate first and second sections, and wherein the gap is elongated and aligned substantially perpendicular to a virtual line extending between a front edge of the first metatarsophalangeal sensor and a rear edge of the fourth metatarsophalangeal sensor; and   a plurality of leads located on the first layer and the second layer, the leads connecting the first contacts and the second contacts to the port and to the pathway.   
     
     
         42 . The system of  claim 41 , further comprising:
 a first resistor located on the first layer and connected to the first conductive portion by one or more leads; and   a second resistor located on the second layer and connected to the second conductive portion by one or more additional leads,   wherein the port, the pathway, the sensors, the leads, and the first and second resistors form a circuit on the insert member, the circuit configured to have a voltage applied between a first terminal and a ground located at the port, and wherein the first and second resistors are arranged in parallel between the first terminal and the ground.   
     
     
         43 . The system of  claim 41 , wherein the gaps of the first and second conductive portions are aligned such that the first section of the first conductive portion engages the first section of the second conductive portion and the second section of the first conductive portion engages the second section of the second conductive portion, with no direct engagement between the first sections and the second sections. 
     
     
         44 . The system of  claim 43 , wherein the first and second conductive portions are circular and the gaps extend across a diameter of each of the first and second conductive portions, such that the first and second sections of each of the first and second conductive portions is semi-circular in shape. 
     
     
         45 . The system of  claim 41 , the pathway further comprising a first substantially annular stiffener located on the first layer and positioned around the first conductive portion and a second substantially annular stiffener located on the second layer and positioned around the second conductive portion, wherein the first and second stiffeners have decreased flexibility compared to the pathway. 
     
     
         46 . The system of  claim 45 , wherein the hole in the spacer layer is larger than the first and second stiffeners, and wherein the first and second layers deflect toward each other through the hole to be in continuous engagement with each other, such that the first and second stiffeners define a substantially annular transition region on each of the first and second layers, wherein the first and second layers deflect toward each other at the transition region and a majority of the first and second conductive portions are in engagement with each other inside an area bounded by the transition region. 
     
     
         47 . 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;   a port connected to the insert and configured for communication with an electronic module;   a plurality of sensors formed on the insert member, each sensor comprising a first contact located on the first layer and a second contact located on the second layer, the sensor configured to sense pressure on the sensor through engagement between the first and second contacts;   a pathway providing electrical communication between the first layer and the second layer, wherein the spacer layer includes a hole located around the pathway to permit the electrical communication between the first and second layers through the pathway, the pathway being located in a position configured to be beneath at least one of a second metatarsophalangeal joint and a third metatarsophalangeal joint of the user; and   a plurality of leads located on the first layer and the second layer, the leads connecting the first contacts and the second contacts to the port and to the pathway.   
     
     
         48 . The system of  claim 47 , wherein the pathway comprises a first conductive portion on the first layer and a second conductive portion on the second layer, wherein the first and second conductive portions are in continuous engagement with each other through the hole to provide electrical communication between the first and second layers. 
     
     
         49 . The system of  claim 48 , wherein the first and second conductive portions each have a gap extending therethrough and dividing the first and second conductive portions into separate first and second sections, and wherein the gaps of the first and second conductive portions are aligned such that the first section of the first conductive portion engages the first section of the second conductive portion and the second section of the first conductive portion engages the second section of the second conductive portion, with no direct engagement between the first sections and the second sections. 
     
     
         50 . The system of  claim 48 , further comprising:
 a first resistor located on the first layer and connected to the first conductive portion by one or more leads; and   a second resistor located on the second layer and connected to the second conductive portion by one or more additional leads,   wherein the port, the pathway, the sensors, the leads, and the first and second resistors form a circuit on the insert member, the circuit configured to have a voltage applied between a first terminal and a ground located at the port, and wherein the first and second resistors are arranged in parallel between the first terminal and the ground.   
     
     
         51 . The system of  claim 47 , wherein the pathway further comprises a substantially annular stiffener positioned around the pathway on at least one of the first and second layers, wherein the stiffener has decreased flexibility compared to the pathway. 
     
     
         52 . The system of  claim 51 , wherein the pathway comprises a first conductive portion on the first layer and a second conductive portion on the second layer, wherein the first and second conductive portions are in continuous engagement with each other through the hole to provide electrical communication between the first and second layers, and wherein the stiffener is located on the first layer and positioned around the first conductive portion, and the pathway further comprises a second substantially annular stiffener located on the second layer and positioned around the second conductive portion, wherein the second stiffener has decreased flexibility compared to the pathway.