Motorized tensioning device with compact spool system

Abstract

A tensioning system for articles of footwear ( 100 ) and articles of apparel is disclosed. The tensioning system includes a tensioning member that is tightened or loosened using a motorized tensioning device for winding and unwinding the tensioning member on a spool. The motorized tensioning device includes a torque transmitting system that allows for incremental tightening, incremental loosening and full loosening of the tensioning member.

1 . A modular footwear apparatus comprising:
 an upper portion including a lace to adjust fit of the upper portion against a foot, the lace adjustable between a first position and a second position based at least in part on manipulation of an effective length of the lace;   a sole structure coupled to the upper portion;   a battery, positioned in the sole structure;   a motorized tensioning device, coupled to the battery, including:
 a lace spool to engage the lace to enable manipulation of the effective length of the lace through rotation of the lace spool; 
 a worm gear operatively coupled to the lace spool; 
 a worm drive engaged with the worm gear; 
 a motor operatively coupled to the worm drive, wherein the motor is configured to turn the worm drive to rotate the worm gear and the lace spool; 
   a control unit, operatively coupled to the lacing engine, configured to cause the lacing engine to rotate the lace spool to adjust between the first position and the second position.   
     
     
         2 . The article of footwear of  claim 1 , wherein the motorized tensioning device further comprises a torque transmitting system configured to transmit torque from the worm drive to the lace spool, wherein torque transmitting system comprises the worm gear and at least one additional gear. 
     
     
         3 . The article of footwear of  claim 2 , wherein the worm drive forms a self-locking mechanism. 
     
     
         4 . The article of footwear of  claim 3 , wherein the motorized tensioning device is configured to switch among the plurality of preset tension settings based on interaction with a user interface. 
     
     
         5 . The article of footwear of  claim 4 , wherein the lacing engine is further configured to transition among a plurality of transitory states to incrementally increase or decrease the effective length of the lace. 
     
     
         6 . The article of footwear of  claim 5 , wherein a decrease of the effective length of the lace corresponds to a tightening of the lace and an increase of the effective length of the lace corresponds to a loosening of the lace. 
     
     
         7 . The article of footwear of  claim 6 , wherein the preset tightened state corresponds to a state including a shortest effective lace length and the preset loosened state corresponds to a state including a longest effective lace length. 
     
     
         8 . The article of footwear of  claim 7 , wherein the user interface is configured to increase the increase the tension on the lace based on touching the user interface in a first location and decrease the tension on the lace based on touching the user interface in a second location. 
     
     
         9 . The article of footwear of  claim 8 , wherein the user interface is positioned between a first layer of the upper and a second layer of the upper and a touch by the user is imparted to the user interface through the first layer. 
     
     
         10 . The article of footwear of  claim 9 , further comprising a wiring portion, wherein the wiring portion further operatively couples the user interface to the power source. 
     
     
         11 . A method of making an article of footwear, comprising:
 engaging a lace with an upper portion including a lace to adjust fit of the upper portion against a foot, the lace adjustable between a first position and a second position based at least in part on manipulation of an effective length of the lace;   coupling a sole structure to the upper portion;   positioning a battery in the sole structure;   coupling a motorized tensioning device to the battery, the motorized tensioning system including:
 a lace spool to engage the lace to enable manipulation of the effective length of the lace through rotation of the lace spool; 
 a worm gear operatively coupled to the lace spool; 
 a worm drive engaged with the worm gear; 
 a motor operatively coupled to the worm drive, wherein the motor is configured to turn the worm drive to rotate the worm gear and the lace spool; 
   operatively coupling a control unit to the lacing engine, the control unit configured to cause the lacing engine to rotate the lace spool to adjust between the first position and the second position.   
     
     
         12 . The method of  claim 11 , wherein the motorized tensioning device further comprises a torque transmitting system configured to transmit torque from the worm drive to the lace spool, wherein torque transmitting system comprises the worm gear and at least one additional gear. 
     
     
         13 . The method of  claim 12 , wherein the worm drive forms a self-locking mechanism. 
     
     
         14 . The method of  claim 13 , wherein the motorized tensioning device is configured to switch among the plurality of preset tension settings based on interaction with a user interface. 
     
     
         15 . The method of  claim 14 , wherein the lacing engine is further configured to transition among a plurality of transitory states to incrementally increase or decrease the effective length of the lace. 
     
     
         16 . The method of  claim 15 , wherein a decrease of the effective length of the lace corresponds to a tightening of the lace and an increase of the effective length of the lace corresponds to a loosening of the lace. 
     
     
         17 . The method of  claim 16 . wherein the preset tightened state corresponds to a state including a shortest effective lace length and the preset loosened state corresponds to a state including a longest effective lace length. 
     
     
         18 . The method of  claim 17 , wherein the user interface is configured to increase the increase the tension on the lace based on touching the user interface in a first location and decrease the tension on the lace based on touching the user interface in a second location. 
     
     
         19 . The method of  claim 18 , wherein the user interface is positioned between a first layer of the upper and a second layer of the upper and a touch by the user is imparted to the user interface through the first layer. 
     
     
         20 . The method of  claim 19 , further comprising a wiring portion, wherein the wiring portion further operatively couples the user interface to the power source.