Reel based closure system

Abstract

To provide a reel type tensioning device which can be used to apply tension to a string or a tension member and thereby tighten an article or other goods, and a component therefor.SOLUTION: A reel based tensioning device includes a housing (102), a spool (140) that is rotatably positioned within the housing, and a knob member (170) that is operably coupled with the spool to cause the spool to rotate in a first direction within the housing and thereby wind a tension member about the spool. The reel based tensioning device also includes a load holding mechanism (120) that is coupled with the spool and that is configured to rotate the spool in the first direction within the housing and to prevent rotation of the spool in a second direction to prevent unwinding of the tension member from about the spool. The reel based tensioning device further includes an audible component that is configured to produce an audible noise responsive to operation of the knob member to signal an adjustment of the tension member.SELECTED DRAWING: Figure 2

Description

[Technical Field]

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims priority to provisional U.S. patent application Ser. No. 62 / 465,342, filed March 1, 2017, entitled "Reel Closure System Employing Friction-Based Tensioning Mechanism." The entire disclosure of the aforementioned provisional U.S. patent application is incorporated herein by reference for all purposes as if fully set forth herein. [Background technology]

[0002]

[0002] The present disclosure relates to reel-type closure devices for various articles, such as orthotics, medical devices, shoes, garments, and apparel. Such articles typically include a closure system that allows the article to be placed around a body part and closed or tightened around the body part. The closure system is typically used to maintain or secure the article around the body part. For example, a shoe is typically placed on an individual's foot, and shoelaces are tensioned and tied to close and secure the shoe around the foot. Traditional closure systems have been modified in an effort to improve the fit and / or comfort of the article around the body part. For example, shoelace configurations and / or patterns have been modified to improve fit and / or comfort when wearing the shoe. Traditional closure systems have also been modified in an effort to reduce the time it takes for the article to be closed and secured around the body part. These modifications have enabled the use of various pull cords, straps, and tensioning devices to quickly close and secure the article to the foot. Summary of the Invention [Means for solving the problem]

[0003] [

[0003] ]The embodiments described herein provide a reel - type tension device and components therefor that can be used to apply tension to a cord or tensile member and thereby clamp an article or other item. According to one aspect, an insert - molded component for a reel - type tension device includes a base member of the reel - type tension device and a fabric material. The base member is typically made of a polymer material and includes an upper end portion and a lower end portion having a bottom surface. The base member has an internal cavity within which one or more components of the reel - type tension device can be disposed. The fabric material is substantially in the same plane as the bottom surface of the base member and extends laterally from at least a portion of the outer periphery of the lower end portion of the base member. The base member is insert - molded onto the fabric material by injecting a polymer material through the fabric material, so that when the insert - molded component is formed, the fabric material is disposed within at least a portion of the base member and the polymer material of at least a portion of the base member is disposed on both sides of the fabric material.

[0004] [

[0004] ]According to another aspect, a component of a reel - type tension system includes a first component that is made of a polymer material and includes an upper end portion, a lower end portion, and an internal cavity within which a second component of the reel - type tension system can be disposed. The component also includes a fabric material that is disposed near the lower end portion of the first component and extends laterally from at least a portion of the outer periphery of the first component. The fabric material is integrally coupled to the first component by injecting the polymer material of the first component through the fabric material, and the polymer material of at least a portion of the first component saturates or impregnates through the fabric material, and the polymer material of at least a portion of the first component extends axially downward from the bottom surface of the fabric material and axially upward from the upper surface of the fabric material.

[0005] According to another aspect, a method of forming a component of a reel-type tension system includes providing a fabric material, disposing the fabric material within a die or mold, and injecting a polymer material through the fabric material to fill a void or space within the die or mold that defines the shape of a first component of the reel-type tension system. The method also includes cooling the polymer material so that the polymer material cures to form a first component of the reel-type tension system. At least a portion of the polymer material of the first component is saturated or impregnated through the fabric material such that at least a portion of the polymer material of the first component extends axially downward from the bottom surface of the fabric material and axially upward from the top surface of the fabric material.

[0006] According to another aspect, a reel-type tension device includes a housing having an internal region and a spool disposed within the internal region of the housing and rotatable relative thereto. The reel-type tension device also includes a knob member operatively coupled to the spool to rotate the spool in a first direction within the internal region of the housing to wind a tension member around the spool, thereby applying tension to the tension member. The reel-type tension device further includes a load holding mechanism coupled to the spool and configured to enable rotation of the spool in the first direction within the internal region of the housing and to prevent rotation of the spool in a second direction within the internal region of the housing to prevent the tension member from being unwound from around the spool. The reel-type tension device further includes an audible component separate from the load holding mechanism and configured to generate an audible noise in response to the operation of the knob member to audibly indicate adjustment of the tension of the tension member.

[0007] According to another aspect, a reel type tension device includes a housing, a spool rotatably disposed within the housing, a knob member operably coupled to the spool to rotate the spool in a first direction within the housing to wind a tension member around the spool, a load holding mechanism coupled to the spool and configured to enable rotation of the spool in the first direction within the housing and prevent rotation of the spool in a second direction within the housing to prevent the tension member from being unwound from around the spool, and an audible component configured to generate an audible noise in response to an operation of the knob member to indicate adjustment of the tension member.

[0008] According to another aspect, a method of constructing a reel type tension device includes providing a reel type tension device, the reel type tension device including a housing, a spool rotatably disposed within the housing, a knob member operably coupled to the spool to rotate the spool in a first direction within the housing to wind a tension member around the spool, and a load holding mechanism coupled to the spool and configured to enable rotation of the spool in the first direction within the housing and prevent rotation of the spool in a second direction within the housing to prevent the tension member from being unwound from around the spool. The method also includes coupling an audible component to the reel type tension device, the audible component being configured to generate an audible noise in response to an operation of the knob member to indicate adjustment of the tension member.

[0009]

[0009] According to another aspect, a reel-type tension device for clamping an article includes a housing having an internal region, a spool disposed within the internal region of the housing and rotatable relative thereto, a knob member operatively coupled to the spool for rotating the spool within the internal region of the housing, and a load holding mechanism coupled to the spool. The load holding mechanism includes a spring that frictionally engages a cylindrical member and prevents the spool from rotating within the internal region of the housing in response to a force applied to the spool from a source other than the knob member, such as the tension of a tension member that applies a rotational force to the spool. Since the knob is operatively coupled to the load holding mechanism, rotation of the knob in a first direction reduces the frictional engagement between the spring and the cylindrical member, enabling the spool to rotate in the first direction within the internal region of the housing, whereby the tension member is wound around the spool. Also, since the knob is operatively coupled to the load holding mechanism, rotating the knob in a second direction also reduces the frictional engagement between the spring and the cylindrical member, enabling the spool to rotate in the second direction within the internal region of the housing, whereby the tension member is unwound from around the spool.

[0010]

[0010] According to another aspect, a reel-type tension device includes a housing, a spool rotatably disposed within the housing, a knob member operatively coupled to the spool for rotating the spool within the housing, and a load holding mechanism including a spring that frictionally engages a cylindrical member to prevent unwanted rotation of the spool within the housing. Since the knob member is operatively coupled to the load holding mechanism, a first operation of the knob member reduces the frictional engagement between the spring and the cylindrical member, enabling the spool to rotate within the housing and causing the tension member to be wound around the spool, and a second operation of the knob member also reduces the frictional engagement between the spring and the cylindrical member, enabling the spool to rotate within the housing and causing the tension member to be unwound from around the spool.

[0011]

[0011] According to another aspect, a method of assembling an article using a reel-type tension device includes providing a reel-type tension device, the reel-type tension device comprising A housing, a spool rotatably disposed within the housing, a knob member operably coupled to the spool for rotating the spool within the housing, and a load holding mechanism including a spring that frictionally engages a cylindrical member to prevent unwanted rotation of the spool within the housing. Since the knob member is operably coupled to the load holding mechanism, a first movement of the knob member reduces the frictional engagement of the spring with the cylindrical member, enabling the spool within the housing to rotate, and the tension member is wound around the spool, and a second movement of the knob member also reduces the frictional engagement of the spring with the cylindrical member, enabling the spool within the housing to rotate, and the tension member is unwound from around the spool. This method also includes coupling a reel type tension device member to an article.

[0012]

[0012] The present invention will be described in conjunction with the accompanying drawings.

Brief Description of the Drawings

[0013] [Figure 1] A perspective view of an assembled reel system showing a knob typically attached to a housing coupled to a base member. [Diagram 2] An exploded perspective view of the reel system of FIG. 1 showing various internal components of the reel system. [Figure 3] An exploded perspective view of the reel system of FIG. 1 showing various internal components of the reel system. [Figure 4] Showing a pawl member or beam of an audible component or mechanism. [Figure 5] A perspective view of the knob member of the reel system of FIG. 1. [Figure 6] Showing an upper hub that can be used in the reel system of FIG. 1. [Figure 7] Showing a lower hub that can be used in the reel system of FIG. 1. [Figure 8] Showing a coil spring that can be used with the upper and lower hubs of FIGS. 6 - 7. [Figure 9] Shows an embodiment of a spool used in the reel system of FIG. 1. [Figure 10] Shows an exploded perspective view of the release hub and the upper hub, lower hub, and coil spring of FIGS. 6 - 8. [Figure 11] Shows an assembled view of the release hub, upper hub, lower hub, and coil spring of FIG. 10. [Figure 12] Shows the knob member and the housing of the reel system of FIG. 1, and the knob member rotates in the tightening direction with respect to the housing. [Figure 13] Shows the knob member and the housing when the knob member rotates in the loosening direction with respect to the housing. [Figure 14] Shows a perspective view of an audible component or mechanism of the reel system of FIG. 1 that can be used to generate audible noise. [Figure 15] Shows a diagram of the base member, the woven fabric material or cloth, and the connection between the base member and the woven fabric material or cloth. [Figure 17] Shows another diagram of the base member, the woven fabric material or cloth, and the connection between the base member and the woven fabric material or cloth. [Figure 18] Shows another diagram of the base member, the woven fabric material or cloth, and the connection between the base member and the woven fabric material or cloth. [Figure 19] Shows another diagram of the base member, the woven fabric material or cloth, and the connection between the base member and the woven fabric material or cloth. [Figure 23] Shows another diagram of the base member, the woven fabric material or cloth, and the connection between the base member and the woven fabric material or cloth. [Figure 24] Shows another diagram of the base member, the woven fabric material or cloth, and the connection between the base member and the woven fabric material or cloth. [Figure 25] Shows another diagram of the base member, the woven fabric material or cloth, and the connection between the base member and the woven fabric material or cloth. [Figure 16] Shows the housing of the reel system of FIG. 1 and various features of the housing. [Figure 20]Shows a stop code or mechanism that can be attached to the spool and housing of the reel system of FIG. 1. [Figure 21] Shows an alternative embodiment of a coil spring and release hub assembly that can be used in the reel system of FIG. 1. [Figure 22] Shows an alternative embodiment of a coil spring and release hub assembly that can be used in the reel system of FIG. 1. [Figure 26] Shows an alternative embodiment of a friction-based load holding mechanism that can be used in the reel system of FIG. 1 and includes a single hub and a coil spring. [Figure 27] Shows an alternative embodiment of a friction-based load holding mechanism that can be used in the reel system of FIG. 1 and includes a single hub and a coil spring. [Figure 28] Shows an alternative embodiment of a friction-based load holding mechanism that can be used in the reel system of FIG. 1 and includes a single hub and a coil spring. [Figure 29] Shows an alternative embodiment of a friction-based load holding mechanism that can be used in the reel system of FIG. 1 and includes a single hub and a coil spring. [Figure 30] Shows an alternative embodiment of a friction-based load holding mechanism that can be used in the reel system of FIG. 1 and includes a single hub and a coil spring.

[0014]

[0030] In the accompanying figures, similar components and / or functions may be labeled with the same reference labels. Further, various components of the same type can be distinguished by following the reference label with a letter to distinguish similar components and / or functions. When only the first numerical reference labels are used in this specification, the description applies to any of the similar components and / or functions having the same first numerical reference label, regardless of the letter suffix.

Best Mode for Carrying Out the Invention

[0015]

[0031] The following description provides only exemplary embodiments and is not intended to limit the scope, applicability, or configuration of the present disclosure. Rather, the following description of exemplary embodiments will provide those skilled in the art with a feasible description for implementing one or more exemplary embodiments. It should be understood that various changes can be made to the functions and arrangements of the elements without departing from the spirit and scope of the invention described in the appended claims.

[0016]

[0032] Embodiments herein describe a reel-type closure device or tensioning device that can be used to apply tension to a string or tension member, thereby clamping an article or other item. Herein, the reel-type tensioning device is also referred to as a reel system or simply a closure device. The article can be various items including a pack (i.e., backpack, book bag, etc.), clothing items (i.e., hat, gloves, belt, etc.), sports clothing (boots, snowboard boots, ski boots, etc.), medical devices (i.e., back brace, knee brace, wrist brace, ankle brace, etc.), and / or other various items or apparel. Specific embodiments in which the closure system can be used include footwear such as shoes, boots, sandals, etc.

[0017]

[0033] The reel system herein employs a friction-based tension adjustment mechanism, which is used to apply tension to a string, cord, or tension member (hereinafter referred to as the tension member) and maintain the tension of the tension member. The friction-based tension adjustment mechanism described herein employs a load-holding mechanism having a spring (e.g., a coil spring) that frictionally engages a cylindrical member such as a boss or hub to provide a load-holding function for maintaining the tension of the tension member. Specifically, the frictional engagement between the spring and the cylindrical member is employed to prevent unwanted rotation of the spool within the housing. Since the reel system is used to maintain the tension of the tensile member, unwanted rotation of the spool means rotation of the spool that is not initiated by the user and that results in the loosening or release of tension of the tensile member. Put another way, the system is designed such that the spool rotates only in response to user actions such as loosening the string or releasing the tension of the string, which typically includes rotating the knob component of the reel system in the loosening direction, but can also include other actions such as operating a lever, pressing a button, or axially pulling up on the knob. When the user does not perform this action, the spring and the cylindrical member are designed to frictionally engage to prevent rotation of the spool within the housing.

[0018]

[0034] The reel system typically includes a knob designed to be grasped and rotated by the user. Since the knob member is operably coupled to a load holding mechanism, a first operation of the knob member (e.g., rotation of the knob in the tightening direction) reduces the frictional engagement between the spring and the cylindrical member, enabling rotation of the spool within the housing and causing the tensile member to be wound around the spool. The knob member is also operably coupled to a load holding mechanism, so a second operation of the knob member (e.g., rotation of the knob in the loosening direction) reduces the frictional engagement between the spring and the cylindrical member, enabling rotation of the spool within the housing and causing the tensile member to be unwound from around the spool.

[0019]

[0035] In an exemplary embodiment, the coil spring is disposed or wound outside the hub member or the central cylindrical boss. The coil spring is configured to contract around the hub member or the central cylindrical boss in order to provide a load holding function. In one embodiment, the hub member or the central cylindrical boss can include an upper hub member fixed to the spool and a lower hub member fixed to the housing. The upper hub member may have a diameter slightly larger than the diameter of the lower hub member. In such an embodiment, the distal end of the upper hub member that joins the lower hub member may be tapered. In another embodiment, the hub member or the central cylindrical boss may be an inner hub member, and the reel system may also include an outer hub member disposed on the inner hub member and operatively coupled to the knob member and the spring, such that when the knob member rotates in the loosening direction, the frictional engagement between the spring and the inner hub member decreases. In such an embodiment, the outer hub member may be coupled to the knob member such that when the knob member rotates in the loosening direction, the outer hub rotates in the loosening direction. The spring may include a tang coupled to the outer hub member, such that when the outer hub member rotates in the loosening direction, the diameter of the spring expands, thereby reducing the frictional engagement between the spring and the inner hub member. In yet another embodiment, the coil spring may be disposed within a cylindrical channel or recess of the boss or hub. In such an embodiment, the coil spring is biased to bend radially outward and frictionally engage the inner wall of the cylindrical channel or recess in order to provide a load holding function.

[0020]

[0036] A friction-based tension adjustment mechanism eliminates the need for a pawl or flexible arm that provides the load-holding function commonly used in conventional systems. In such conventional systems, the pawl or arm generally engages teeth to provide the load-holding function. The pawl / arm and teeth are often inclined or configured to allow one-way movement of the pawl / arm, such as rotation of a knob in the tightening direction, thereby enabling a reel-type device. When the knob rotates in the opposite direction, the pawl / arm and teeth lock engage, preventing rotation of one or more components of the system that loosen the tension of the tension member. Embodiments herein may not include a pawl or arm that functions to provide a load-holding capacity at all. In other embodiments, the reel system may include a combination of a friction-based mechanism and a pawl or arm to provide a load-holding function.

[0021]

[0037] The load-holding mechanism (i.e., spring and hub member) described herein may not generate audible noise detectable by the human ear. Thus, the reel system may include an audible component configured to generate audible noise in response to operation of the knob member to indicate adjustment of the tension member. The audible component may be configured to generate audible noise in response to applying tension to the tension member and to generate audible noise in response to loosening the tension member. The audible noise generated in response to applying tension to the tension member may be different from the audible noise generated in response to loosening the tension member. The audible component may be coupled to the upper surface of the spool.

[0022]

[0038] The systems of this specification generally lack load retaining jaws or arms, but in exemplary embodiments, a separate jaw system, member, or beam may be used to generate audible noise or sound when the system is in operation. For example, the jaw system, member, or beam is used primarily to generate a clicking sound when the knob rotates, and the clicking sound audibly indicates to the user that the system is being used to pull or release a tension member. The jaw system, member, or beam may provide audible feedback that the user of the system expects and / or desires. The jaw system, member, or beam may not be able to prevent rotation of a spool within a housing when a significant rotational force is applied to the spool via a tension member or knob member. For example, when the user rotates the knob member in the loosening direction, the jaw system, member, or beam may not impede the rotation of the knob member very much.

[0023]

[0039] Additional features and aspects of the reel-type closure device will become apparent upon reference to the descriptions of several of the drawings provided hereinbelow.

[0024]

[0040] Figure 1 shows an assembled perspective view of the reel system 100. The assembled reel system 100 shows a knob 170 attached to a housing 102, which is typically coupled to a base member 220. The housing 102 is coupled to the base member 220 such that the housing 102 can be removed or detached from the base member 220. The coupling of the housing 102 to the base member is achieved through the engagement of mating features disposed on both components. Figure 1 shows a lip or flange member 106 that can be disposed within a front tab 222 of the base member 220 to couple the front portion of the housing 102 to the base member 220. Figure 16 shows a tab 110 disposed on the opposite side of the housing 102. The tab 110 is designed to fit within a corresponding slot on the inner surface of a wall 224 that partially surrounds the base member 220. Figure 16 also shows a race port 104 of the housing 102. The race port includes an opening 105 through which a tension member is inserted to allow access of the tension member into the interior of the housing 102. As shown in Figure 17, the base member 220 includes openings or regions on both sides of the front tab 222 that are shaped and sized to accommodate the race port 104, showing the appearance of the base member 220 and the housing 102 as a single component.

[0025]

[0041] The housing 102 is shaped to correspond to the outer surfaces of the base member 220 and the knob 170. For example, when the housing 102 is attached to the base member 220, the outer surfaces of these components align such that they appear continuous or flush. The alignment of the outer surfaces of the housing 102 and the base member 220 serves to make the edges of both components less visible or hidden. In this way, the user does not readily recognize the separate edges of the components, but rather visually perceives the separate components as an integrated unit. The outer surface of the housing 102 is similarly aligned with the knob 170, such that the outer surfaces appear to flow together. The alignment of the knob 170 and the outer surface of the housing 102 eliminates or minimizes ridges or edges that could catch on surrounding objects and open the system or remove the knob 170 from the housing 102. The shapes of the housing 102, the knob 170, and the base member 220 provide a visually appealing appearance that the user desires.

[0026]

[0042] The knob 170 is coupled to the housing 102 via a snap engagement or fit. Specifically, the inner surface of the knob 170 includes radially inwardly projecting tabs 176 configured to snap onto ribs 114 that project radially outwardly from the housing 102. The knob 170 is capable of bending slightly radially outward when the two components are snap fit together. The snap fit engagement or coupling allows the components to be attached together without using screws, bolts, or other similar mechanical fasteners. An exemplary embodiment of the snap fit coupling of the knob and the housing is further described in U.S. Patent Application No. 14 / 297,047, filed on June 5, 2014, and titled "Components and Methods of an Integrated Closure Device", the entire disclosure of which is incorporated herein by reference.

[0027]

[0043] Figures 1 and 5 show a knob 170 having a textured or patterned outer rim 173 that may, in some cases, have a knurled configuration. The textured or patterned outer rim can enhance the grip surface of the rim 173 of the knob 170 and / or can be used for aesthetic appeal. In some cases, the knob 170 may be made of a metallic material such as aluminum or stainless steel. In such cases, the textured or patterned outer rim 173 can significantly enhance the grip characteristics of the knob 170. In other examples, the knob 170 may be made of a plastic material such as polypropylene, polyethylene, nylon, etc.

[0028]

[0044] Figures 2 and 3 show an exploded perspective view of the reel system 100. The internal components of the reel system 100 can be seen in Figures 2 and 3. The term "internal components" means system components that are disposed within the internal region 116 of the housing 102 and axially below the knob 170 and that are not visible in the assembled view. The internal components include a spool 140, a friction-based load holding mechanism 120, an audible feedback assembly 160, and a stop code or mechanism 230 (see Figure 20). Each of these components will be described in more detail in connection with Figures 2 - 20, which provide detailed perspective views of the various components.

[0029]

[0045] The spool 140 is rotatably disposed within the inner region 116 of the housing 102. A detailed perspective view of the spool 140 is shown in FIG. 9. The spool 140 is configured to rotate about a cylindrical coupling post 190 attached to the central boss 115 of the housing 102. The cylindrical coupling post 190 is inserted through the central opening 148 of the spool 140 and attached to the central boss 115 of the housing 102 by inserting or press-fitting the distal end of the cylindrical coupling post 190 into the opening of the central boss 115 of the housing (see FIG. 16). FIG. 16 shows the cylindrical coupling post 190 press-fitted or inserted into the opening of the central boss 115. The cylindrical coupling post 190 can be fixed to the central boss 115 via an interference fit, adhesive bonding, welding (RF, ultrasonic, etc.). The opening 148 of the spool is large enough to minimize the frictional force between the spool 140 and the cylindrical coupling post 190, thereby allowing the spool 140 to freely rotate about the cylindrical coupling post 190 within the inner region 116 of the housing 102.

[0030]

[0046] The opening 148 of the spool is disposed centrally within a recess in the upper surface of the spool 140. The recess in the upper surface of the spool 140 is shaped and sized to accommodate a cap of the cylindrical coupling post 190. When the cap of the cylindrical coupling post 190 is disposed within the recess of the spool 140, the upper surface of the cap can be aligned with the upper surface of the spool 140.

[0031]

[0047] The spool 140 includes a wire winding area such as an annular channel 144 around which a tension member (not shown) is wound or rewound to apply or release tension to the tension member. The spool 140 is operably coupled to the knob 170, and rotation of the knob 170 in the tightening direction (e.g., clockwise) and the loosening direction (e.g., counterclockwise) causes the spool 140 to rotate correspondingly within the internal region 116 of the housing 102. The knob 170 includes one or more drive components or tabs 174 disposed within the window 150 of the spool 140. In the illustrated embodiment, the reel system 100 includes three drive tabs 174 and three windows 150, although more or fewer of these components can be used as desired.

[0032]

[0048] The drive tabs 174 are sized smaller than the windows 150 and can rotate to some extent within the windows 150 between the opposing inner or edge portions 152 of the windows 150. Relative rotation of the drive tabs 174 within the windows 150 allows the knob 170 to be rotated to some extent around the housing 102 without causing tightening or loosening of the tension member. As described herein, the smaller-sized drive tabs 174 facilitate release of the friction-based load holding mechanism 120. The drive tabs 174 shown in FIGS. 12 and 13 rotate between the opposing side portions 152 of the windows 150 and are used in a manner that allows the spool 140 to be rotated within the internal region 116 of the housing 102 to apply or release tension to the tension member.

[0033]

[0049] The bottom or rear surface of the spool 140 includes a large cylindrical opening or channel 142 in which the friction-based load holding mechanism 120 is disposed. As shown in FIG. 10, the friction-based load holding mechanism 120 includes an upper hub 126, a lower hub 122, a coil spring 134, and a release sleeve 130, all or most of which are coaxially aligned and disposed within the opening or channel 142 of the spool 140. The upper hub 126, the lower hub 122, and the release sleeve 130 all include axially extending teeth. Specifically, the upper hub 126 includes axially extending teeth 128, the lower hub includes axially extending teeth 124, and the release sleeve 130 includes axially extending teeth 132. The axially extending teeth 128 and 124 of the upper hub 126 and the lower hub 122 are oriented such that the teeth extend in opposite directions. The release sleeve 130 is oriented such that its axially extending teeth 132 extend in the same direction as the axially extending teeth 128 of the upper hub 126.

[0034]

[0050] The upper hub 126 is disposed within the cylindrical opening 142 of the spool 140, and its axially extending teeth 128 are inserted into corresponding openings 158 of the spool 140, whereby the upper hub 126 is locked or fixed to the spool 140. Fixing the upper hub 126 to the spool 140 means that the upper hub 126 does not translate or rotate relative to the spool 140. Rather, the rotational movement or translation of the spool 140 causes a corresponding rotational movement or translation of the upper hub 126 because the two components are fixed to each other. Similarly, the lower hub 122 is disposed within the internal region 116 of the housing 102, and its axially extending teeth 124 are inserted into corresponding openings 107 of the housing 102 to lock or fix the lower hub 122 to the housing 102. When coupled to the base member 220, the housing 102 is fixed in place relative to the base member 220. Since the lower hub 122 is locked or fixed to the housing 102, the lower hub 122 is fixed in place relative to the base member and the housing, and thus the lower hub 122 is not rotatable or translatable relative to the reel system 100.

[0035]

[0051] The coil spring 134 is disposed on the upper hub 126 and the lower hub 122. The release sleeve 130 is disposed over the coil spring 134 such that the coil spring 134, the upper hub 126, and the lower hub 122 are disposed within the cylindrical inner region of the release sleeve 130. The coil spring 134 surrounds the upper hub 126 and the lower hub 122 such that the coil spring 134 can contract around the outer surfaces of these hubs 126 and 122. Specifically, the inner diameter of the coil spring 134 is approximately the same as or slightly smaller than the outer diameters of the upper hub 126 and the lower hub 122. The coil spring 134 frictionally engages the upper hub 126 and the lower hub 122 by contracting around the outer surfaces of the hubs 122 and 126. The frictional engagement between the coil spring 134 and the upper hub 126 and the lower hub 122 provides the load holding characteristics or functions of the friction-based load holding mechanism 120. Specifically, by contracting the coil spring 134 around the upper hub 126 and the lower hub 122, the upper hub 126 is prevented from rotating around or relative to the lower hub 122, thereby locking or fixing the upper hub 126 and the lower hub 122 to each other. When the upper hub 126 and the lower hub 122 are locked together in this manner, since the spool 140 is fixed to the upper hub 126, the spool 140 is locked in place relative to the housing 102. Thereby, the spool 140 is prevented from spinning or rotating within the inner region 116 of the housing 102, and the tension present in the tensile member is maintained.

[0036]

[0052] When the knob 170 rotates in the tightening direction (e.g., arrow A in FIG. 12), the coil spring 134 is designed to be able to rotate around the lower hub 122 fixed in position around the housing 102. The coil spring 134 typically remains fixed in place around the upper hub 126 and rotates in the tightening direction together with the upper hub 126, the release sleeve 130, the spool 140, and the knob 170. Maintaining proper alignment of the upper hub 126, the coil spring 134, and the release sleeve 130 is important for achieving a consistent repeatable sense of tension and slack and performance of the reel system 100 as described herein. When these components rotate in the tightening direction, the tension member is wound around the annular channel 144 of the spool 140, thereby increasing the tension of the tension member. When the rotation of the knob 170 in the tightening direction stops, the coil spring 134 contracts around the upper hub 126 and the lower hub 122, thereby locking or fixing these components together and preventing rotation of the spool 140 and other components in the loosening direction (e.g., arrow B in FIG. 13). The tension of the tension member typically biases the spool 140 towards rotation in the loosening direction, thereby increasing the frictional engagement between the coil spring 134 and the upper hub 126 and the lower hub 122. The increased frictional engagement of these components further locks or fixes the upper hub 126 and the lower hub 122 together.

[0037]

[0053] The release sleeve 130 is used to adjust the frictional engagement of the coil spring 134 around the upper hub 126 and the lower hub 122 to allow the hubs 126 and 122 to rotate relative to each other, thereby allowing the spool 140 to rotate within the internal region 116 of the housing 102. Specifically, the release sleeve 130 is operably coupled to the knob 170, and when the knob 170 rotates in the loosening direction, the lower portion of the release sleeve 130 rotates in the loosening direction. As shown in FIG. 13, when the knob 170 rotates in the loosening direction, the drive tab 174 of the knob 170 engages the axially extending teeth 132 of the release sleeve 130, causing the release sleeve 130 to rotate in the loosening direction.

[0038]

[0054] As shown in FIG. 11, the end portion of the release sleeve 130 on the opposite side is attached to a tang 136 that extends radially of the coil spring 134. When the release sleeve 130 rotates in the loosening direction, the tang 136 is pushed, and the coil spring 134 opens slightly. Specifically, when the release sleeve 130 rotates in the loosening direction, the tang 136 is pushed and rotated in the loosening direction. As a result, the lower coil portion of the coil spring 134 opens or expands radially, thereby reducing the frictional engagement between the lower coil portion and the lower hub 122. The reduction in the frictional engagement between the coil spring 134 and the lower hub 122 allows the lower coil portion of the coil spring 134 to rotate in the loosening direction around the lower hub 122.

[0039]

[0055] Since the upper part of the coil spring 134 remains fixed in place around the upper hub 126, the upper part of the coil spring 134 does not rotate around or relative to the upper hub 126. Since the lower part of the coil spring 134 is rotatable around the lower hub 122 via the release sleeve 130, the upper hub 126 and the coil spring 134 can rotate in the loosening direction. In this way, the release sleeve 130 enables the upper hub 126 to be unlocked or decoupled from the lower hub 122, and thereby, in response to rotation of the knob 170 in the loosening direction, the upper hub 126 and the coil spring 134 can be rotated in the loosening direction. Since the upper hub 126 is attached to the spool 140, when the connection between the upper hub 126 and the lower hub 122 is released, the spool 140 can be rotated in the loosening direction in response to rotation of the knob 170 in the loosening direction, whereby the tension member is wound back from the annular channel 144 and the tension of the tension member is reduced. When the rotation of the knob 170 in the loosening direction stops, the lower part of the coil spring 134 contracts around the lower hub 122, thereby locking or coupling the upper hub 126 and the lower hub 122, and thereby preventing the upper hub 126, the coil spring 134, and the spool 140 from rotating further in the loosening direction.

[0040]

[0056] The release sleeve 130 is sized larger radially than the coil spring 134, ensuring that the release sleeve 130 does not frictionally engage with or minimally engages with the coil spring 134, and this engagement prevents rotation of the release sleeve 130 relative to the coil spring 134.

[0041]

[0057] As briefly described above, it is desirable to maintain the orientation of the upper hub 126, the coil spring 134, the release sleeve 130, and the spool 140. The proper orientation of these components is important to ensure that when the knob 170 is rotated in the loosening direction, the release sleeve 130 engages the tang 136 in a consistent and repeatable manner, thereby maintaining the tensioning and loosening of the tension member relatively constant. As shown in FIGS. 12 and 13, the axially extending teeth 132 and the drive tab 174 are disposed within the window 150 of the spool 140. To achieve repeatable and consistent engagement of the tang 136, it is important to maintain the orientation or relative position of the axially extending teeth 132 and the drive tab 174 within the window 150. Otherwise, the drive tab 174 will not properly engage the axially extending teeth 132 of the release sleeve 130, rotate the release sleeve 130, and open the lower coil portion of the coil spring 134 as described above.

[0042]

[0058] To maintain the orientation of these components, it is important that the upper coil portion of the coil spring 134 remain fixed about the upper hub 126. Specifically, it is important that the coil spring 134 does not rotate relative to the upper hub 126, but only rotates relative to or around the lower hub 122. To ensure that the coil spring 134 rotates only about the lower hub 122 and remains fixed or secured to the upper hub 126, one or more of the following upper and lower hub configurations may be used: the upper hub 126 may have a slightly larger diameter than the lower hub 122; the upper hub 126 may be made of a material with a greater coefficient of friction than the lower hub 122; the lower hub 122 may have a surface finish that substantially reduces the coefficient of friction compared to the upper hub 126; etc. Any combination of these options may be used to ensure that the coil spring 134 rotates only about the lower hub 122.

[0043]

[0059] For example, as shown in FIGS. 6 and 7 , the upper hub 126 may have a diameter D1 that is larger than the diameter D2 of the lower hub 122. The larger diameter D1 of the upper hub 126 ensures that the coil spring 134 can contract around the upper hub 126 and frictionally engage it more than the lower hub 122. In some embodiments, the difference in diameter between the upper hub 126 and the lower hub 122 is approximately 2 mm. A 2 mm difference in diameter is sufficient to ensure that the coil spring 134 remains frictionally engaged and secured to the upper hub 126 without significantly affecting the load-holding capacity of the system, which may occur if the difference in diameter between the upper hub 126 and the lower hub 122 is too large. If the difference in diameter between the upper hub 126 and the lower hub 122 is too large, the coil spring 134 may not be able to contract sufficiently around the lower hub 122 and, therefore, may not be able to lock or secure the upper hub 126 and the lower hub 122 together.

[0044]

[0060] To ensure that the coil spring 134 can properly contract around hubs of different sizes, the upper hub 126 includes a tapered distal end 127, which provides a transition between the upper hub 126 of larger diameter and the lower hub 122 of smaller diameter. The tapered distal end 127 ensures that no rough step or sharp edge is formed at the interface between the two hubs, as these rough steps or sharp edges can potentially affect the holding force of the reel system 100 by limiting the ability of the coil spring 134 to grip and contract around the outer surface of the lower hub 122. Due to the tapered distal end 127, the coil spring 134 can tighten and grip around the outer surface of the lower hub 122 despite the size difference between the upper and lower hubs. Further, the upper hub 126 may be made of a material having a higher coefficient of friction than the lower hub 122. For example, the upper hub 126 may be made of aluminum, and the lower hub 122 may be made of brass or bronze. The surface finish of the lower hub 122 can further or alternatively reduce the coefficient of friction of the lower hub 122. For example, the lower hub 122 may have a polished surface finish compared to the upper hub 126, thereby substantially reducing the coefficient of friction of the lower hub 122.

[0045]

[0061] To maintain the orientation of the component, it is also important to ensure proper alignment of the release sleeve 130 and the tang 136 of the coil spring. The alignment of the release sleeve 130 and the tang 136 is important because upon rotation of the release sleeve 130 in the loosening direction, the tang 136 is immediately and surely engaged therewith. In some cases, the distal end of the release sleeve 130 may include a notch or slot in which the tang 136 is disposed. However, in the present embodiment, as shown in FIG. 11, the tang 136 is directly inserted into the distal end of the release sleeve 130. One way to directly insert the tang 136 into the distal end of the release sleeve 130 is by thermally caulking the tang 136 to the release sleeve 130. Inserting the tang 136 directly into the release sleeve 130 eliminates or substantially minimizes problems associated with manufacturing tolerances, which can vary the relative position of the tang 136 around the release sleeve 130 and significantly affect the way the coil spring 134 opens in response to reverse rotation of the knob 170 and the release sleeve 130.

[0046]

[0062] Since the coil spring 134 is wound around the upper and lower hubs a plurality of times, a change in the diameter of either hub 126 or 122 can significantly affect the position of the tang 136 relative to the release sleeve 130. For example, if the diameter of either hub changes, the position of the tang 136 relative to the release sleeve 130 changes, which can be modeled by the equation V = NπΔD, where V is the variation in the position of the tang 136 around the release sleeve 130, N is the number of turns of the coil spring 134, and ΔD is the change in the diameter of either hub. Slight variations in the diameter of either or both of hubs 126 and 122 can change the position of tang 136 by up to 1 mm, and it has been observed that this significantly affects the degree to which coil spring 134 opens or expands in response to counter-rotation of release sleeve 130. By thermally staking or otherwise directly inserting tang 136 into the distal end of release sleeve 130, the potential effects of variations in the components of reel system 100 are nullified. Rather, by directly inserting tang 136 into release sleeve 130, proper and accurate alignment is ensured regardless of the variations experienced in the system. By eliminating or reducing variations in the positioning of tang 136 around release sleeve 130, typically a more consistent and reproducible system performance, and a feel of applying and releasing tension to the tension member, are obtained.

[0047]

[0063] In some embodiments, coil spring 134 may be wound around upper hub 126 and lower hub 122 approximately seven times.

[0048]

[0064] Figures 12 and 13 show the interaction of the knob 170, the spool 140, and the release sleeve 130 when adjusting the tension of the tension member. Figure 12 shows these components used to increase the tension of the tension member by winding the tension member around the annular channel 144 of the spool, while Figure 13 shows these components used to decrease the tension of the tension member by unwinding the tension member from around the annular channel 144 of the spool. In the figures, the upper surface of the knob 170 is removed, and the drive tab 174 of the knob 170, the axially extending teeth 132 of the release sleeve 130, the upper surface of the spool 140, and the window 150 of the spool are visible. As shown in Figure 12, when the knob 170 rotates in the tightening direction represented by arrow A, the drive tab 174 contacts the first tooth 132a of the release sleeve 130 and the front edge 152a of the window 150 of the spool (in Figure 13, the first tooth 132a is shown exposed). Due to the contact between the drive tab 174 and the first tooth 132a, the release sleeve 130 rotates relative to the spool 140, whereby the first tooth 132a exits the window 150 and rotates under the upper surface of the spool 140. When the release sleeve 130 is rotated in this way, as shown in Figure 12, the second tooth 132b rotates towards the inside of the window 150 on the opposite side of the drive tab 174.

[0049]

[0065] Due to the contact between the drive tab 174 and the front edge 152a of the window 150 of the spool, a rotational force is transmitted between the knob 170 and the spool 140. Thus, when the knob 170 rotates in the tightening direction, the spool rotates in the same tightening direction, whereby the tension member is wound around the annular channel 144 of the spool. As shown, this embodiment includes three drive tabs 174, windows 150, and first teeth 132a, although more or fewer of these components may be used. In some embodiments, the release sleeve 130 does not include the first teeth 132a, and instead, the rotational force is transmitted to the release sleeve 130 via a coil spring 134 and a tang 136.

[0050]

[0066] As shown in FIG. 13, by rotating the knob 170 in the opposite direction (i.e., the loosening direction) indicated by the arrow B, the drive tab 174 rotates counterclockwise or in the opposite direction within the window 150. As described herein, this counterclockwise rotation of the drive tab 174 causes the drive tab to contact the second tooth 132b and rotate the second tooth 132b and the release sleeve 130 in the loosening direction, whereby the release sleeve 130 rotates the tongue 136 of the coil spring, opening or expanding the diameter of the coil spring 134. The rotation of the drive tab 174 pushes the second tooth 132b out from the window 150 under the upper surface of the spool 140 until the drive tab 174 contacts the second edge 152b of the window. The first tooth 132a rotates simultaneously within the window as shown. In this way, the knob 170 is rotatable in the loosening direction and engages with the release sleeve 130, thereby reducing the frictional engagement of the coil spring 134 around the lower hub 122, whereby the spool 140, the upper hub 126, and the coil spring 134 rotate in the loosening direction, thereby reducing the tension of the tension member by rewinding the tension member from the annular channel 144 of the spool. The tension of the tension member and / or the drive tab 174 pressing against the second edge 152b can rotate the spool 140 in the loosening direction.

[0051]

[0067] Since the drive tab 174 is rotatable within the window 150 between the first edge 152a and the second edge 152g, the knob 170 rotates to some extent relative to the spool 140 before engaging with the spool 140 and rotating the spool 140 in the tightening or loosening direction. In some embodiments, the knob 170 can rotate 3 to 20 degrees relative to the spool 140 before engaging with the spool, although a rotation between 5 and 10 degrees is more common. The relative rotation of the knob 170 around the spool 140 is important to ensure contact with the second tooth 132b before the drive tab 174 contacts the second edge 152b. This allows the release sleeve 130 to rotate relative to the spool 140 and rotate relative to the upper hub 126 and the lower hub 122, whereby, as described above, the coil spring 134 opens and the frictional engagement between the coil spring 134 and the lower hub 122 is reduced.

[0052]

[0068] When the drive tab 174 contacts the second tooth 132b and the second edge 152b simultaneously or substantially simultaneously, the coil spring 134 does not open fully and remains in frictional engagement with the lower hub 122. This frictional engagement between the coil spring 134 and the lower hub 122 requires the user to apply a significant force to loosen the tension member and / or can give the impression that the system is locked, jammed, or otherwise malfunctioning. Therefore, maintaining the proper orientation of the teeth 132a and 132b of the release sleeve with respect to the window 150 and the drive tab 174 is highly desirable to provide a more consistent and comfortable user experience. The above approach of fixing the coil spring 134 to the upper hub 126 and inserting the tang 136 directly into the release sleeve 130 helps to ensure the proper orientation of the upper hub 126, the coil spring 134, the release sleeve 130, and the spool 140, thereby providing a more uniform and consistent feel and operation of the reel system 100.

[0053]

[0069] Referring briefly to FIGS. 26 - 30, an alternative embodiment of a friction-based load holding mechanism including a single hub 180 that frictionally engages a coil spring 182 is shown. The hub 180 and the coil spring 182 are configured to be coaxially aligned and disposed within an opening or channel 142 of the spool 140. The hub 180 includes axially extending teeth 124 that fix the hub 180 to the housing 102. The coil spring 182 includes a U-shaped tang 184 configured to couple with the spool 140 by being disposed within a channel 141 at the lower end of the spool 140 as shown in FIG. 30. The U-shaped tang 184 eliminates the need for the upper end of the hub 180 to include axially extending teeth that engage the spool 140, and this design may be employed with the upper hub 126 described herein. The tang 184 may also have a shape other than the U-shape shown in FIGS. 26 - 30. The spool 140 is fixed to the housing 102 via the engagement of the axially extending teeth 124 of the hub 180 and the tang 184 of the hub 180.

[0054]

[0070] FIG. 27 shows a coil spring 182 wound around the outer surface of a single hub 180. As described herein, the coil spring 182 is designed to contract around the hub 180, thereby frictionally engaging with the hub 180 to prevent unwanted rotation of the spool 140 within the housing 102. The frictional engagement between the coil spring 182 and the hub 180 provides the load-holding characteristics or function of a friction-based load-holding mechanism. Specifically, the contraction of the coil spring 182 around the hub 180 locks or fixes the spring 182 around the hub 180, and since the spool 140 is fixed to the hub 180, the spool 140 is locked or fixed in place relative to the housing 102. Accordingly, unwanted rotation of the spool 140 within the housing 102 is prevented.

[0055]

[0071] The knob 170, spool 140, and coil spring 182 are designed such that when the knob 170 rotates in the tightening direction (e.g., arrow A in FIG. 12), the spool 140 and coil spring 182 can rotate around the hub 180 that is fixed in place around the housing 102. To enable the spool 140 and coil spring 182 to rotate around the hub 180, the knob 170 includes axially extending protrusions 171 and 175 disposed within corresponding recesses 143 and 145 of the spool 140. The axially extending protrusions 171 and 175 contact and engage the corresponding recesses 143 and 145 of the spool 140 to transmit the rotational force applied to the knob 170 by the user. Due to the rotational force, the spool 140 rotates around the hub 180. The coil spring 182 can rotate around the hub 180 by virtue of its connection to the U-shaped tang 184 and the spool 140. Specifically, when the spool 140 rotates in the tightening direction, the rotation of the spool 140 transmits the rotational force to the U-shaped tang 184, thereby expanding the diameter of the coil spring 182 and reducing the frictional engagement between the coil spring 184 and the hub 180 to the point where rotation of the coil spring 182 around the hub 180 becomes possible. When rotation of the knob 170 in the tightening direction stops, the coil spring 182 immediately re-engages with the hub 180, thereby locking or fixing the spool 140 in place relative to the housing 102.

[0056]

[0072] When the knob 170, spool 140, and coil spring 182 rotate in the direction in which the knob 170 loosens (e.g., arrow B in FIG. 13), the spool 140 and coil spring 182 are also designed to be able to rotate around a hub 180 that is fixed in place around the housing 102. The knob includes a release protrusion 179 configured to contact and engage the upper tongue 186 of the coil spring 182 when the knob 170 rotates in the loosening direction. The engagement between the release protrusion 179 and the upper tongue 186 transmits the rotational force to the upper tongue 186, whereby the diameter of the coil spring 182 expands, and the frictional engagement between the coil spring 182 and the hub 180 decreases to the point where the coil spring 182 can rotate around the hub 180. Since the frictional engagement between the coil spring 182 and the hub 180 decreases, the spool 140 rotates in the loosening direction due to the tension of the tensile member and / or the rotational force applied to the knob 170. When the rotation of the knob 170 in the loosening direction is stopped, the coil spring 182 immediately re-engages with the hub 180, whereby the spool 140 is locked or fixed in place relative to the housing 102.

[0057]

[0073] A method of assembling an article using a reel-type tension device may include providing a reel-type tension device, the reel-type tension device including a housing, a spool rotatably disposed within the housing, a knob member operatively coupled to the spool for rotating the spool within the housing, and a load holding mechanism including a spring that frictionally engages a cylindrical member to prevent unwanted rotation of the spool within the housing. The knob member is operatively coupled to the load holding mechanism such that a first operation of the knob member reduces the frictional engagement between the spring and the cylindrical member, enabling rotation of the spool within the housing and allowing a tensile member to be wound around the spool, and a second operation of the knob member reduces the frictional engagement between the spring and the cylindrical member, enabling rotation of the spool within the housing and allowing the tensile member to be unwound from around the spool. The method may also include coupling the reel-type tension device member to an article.

[0058]

[0074] The spring may be a coil spring wound around the outside of a cylindrical hub member, and the coil spring frictionally engages the hub member by contracting around the outer surface of the hub member. In some embodiments, the hub member may include an upper hub member fixed to the spool and a lower hub member fixed to the housing. The upper hub member may have a diameter slightly larger than the diameter of the lower hub member, and the distal end of the upper hub member that joins the lower hub member may be tapered. Alternatively or additionally, the hub member may be an inner hub member, and the reel-type tension device may also include an outer hub member disposed on the inner hub member and operatively coupled to the knob member and the spring, such that when the knob member is rotated in the loosening direction, the frictional engagement between the spring and the inner hub member is reduced. The outer hub member is coupled to the knob member such that when the knob member is rotated in the loosening direction, the outer hub rotates in the loosening direction. The spring may include a tang that couples to the outer hub member, and when the outer hub member rotates in the loosening direction, the diameter of the spring expands, thereby reducing the frictional engagement between the spring and the inner hub member. In other embodiments, the cylindrical member may include a cylindrical channel or recess, and the spring may be a coil spring radially biased to frictionally engage the inner wall of the cylindrical channel or recess.

[0059]

[0075] The friction-based load holding mechanism 120 is typically a silent mechanism, which means that the friction-based load holding mechanism 120 essentially does not generate audible sound or minimizes the amount of audible noise generated. The description of non-detectable / detectable inaudible noise used herein refers to a noise level lower than that outlined in MIL-STD-1474D, Req.2, pages 20 - 32, the entire disclosure of which is incorporated herein by reference. In some cases, it may be desirable to provide audible feedback regarding the use of the reel system 100. To provide audible feedback, the reel system 100 may include a separate audible mechanism such as a pawl system that generates an audible click sound when the reel system 100 is in operation. FIG. 14 shows an assembly of components of a system that can be used to generate an audible click sound, and FIG. 4 shows the pawl member 160 of the audible mechanism. The pawl member 160 includes an elongated body, a first end 162, and a second end 164. The first end 162 is configured to couple with the upper surface of the spool 140, and the second end 164 is configured to interact with the teeth 112 located in the internal region 116 of the housing 102.

[0060]

[0076] As shown in FIG. 14, the first end 162 of the pawl member 160 is disposed within the coupling slot or recess 156 of the spool 140. In this embodiment, the first end 162 of the pawl member 160 is bent to form a loop that fits within the slot or recess 156 of the spool 140, although other methods of attaching the first end 162 of the pawl member to the spool may be employed. When disposed within the housing 102, the pawl member 160 bends and flexes between the first end 162 and the second end 164. The elongated body of the pawl member 160 is disposed radially outside of the central portion 159 of the spool 140 and is bent around the central portion 159. In some embodiments, the pawl member 160 may be disposed radially inside of the outer protrusion 157 of the spool 140. The outer protrusion 157 may hold the pawl member 160 in a predetermined position during the assembly of the reel system 100 and / or may affect the flexibility of the pawl member 160 to generate a desired audible sound.

[0061]

[0077] The second end portion 164 of the pawl member 160 contacts the inner surface of the housing 102 and the teeth 112. The second end portion 164 may be shaped such that the second end portion 164 slides easily around the inner surface of the housing 102 and deflects in and out of the teeth 112. In one embodiment, the second end portion 164 of the pawl member has a U-shape, whereby the second end portion 164 can slide easily around the inner surface of the housing, minimizing the engagement between the second end portion 164 of the pawl member 160 and the teeth 112 that would interfere with or impede such movement. Unlike conventional pawls, the second end portion 164 of the pawl member 160 is not designed to limit or significantly resist the rotation of the spool 140 within the housing 102.

[0062]

[0078] When the spool 140 rotates in the tightening or loosening direction within the housing 102, the second end portion 164 deflects in and out of the adjacent teeth 112 of the housing 102. The second end portion 164 generates an audible click sound when the second end portion 164 bounces or rebounds and engages each tooth 112 of the housing 102. When the spool 140 rotates in one direction, tension is applied to the pawl member 160, and the second end portion 164 is drawn in or out of each tooth 112 of the housing 102. When the spool 140 rotates in the opposite direction, the pawl member 160 is compressed, and the second end portion 164 is pushed into or out of each tooth 112. In this way, an audible click sensation is generated when the reel system 100 operates to both apply and release tension to the tension member.

[0063]

[0079] The second end 164 of the pawl member 160 may be configured to generate a substantially uniform sound regardless of the direction of rotation of the spool, or may be configured to generate different sounds when the spool 140 rotates in the tightening direction and when it rotates in the loosening direction. For example, the second end 164 is configured to respond slightly differently when pulled to engage each tooth 112 and when pushed to engage each tooth, thereby generating different audible sounds. The sound can also be adjusted by selecting the thickness of the pawl member 160, the length of the pawl member 160, and / or the number of teeth used in the system. In some embodiments, the spool 140 can include from about 20 to 40 teeth, more generally from about 25 to 35 teeth. In a particular embodiment, the spool 140 can include 32 teeth. The reel system 100 can also implement a plurality of pawl members (e.g., two or more), and each pawl member is used while pulling or loosening the tension member. In other embodiments, the audible mechanism may include a detent that engages to generate an audible sound, or a linear pawl beam that interacts with the spline teeth.

[0064]

[0080] A method of constructing a reel-type tension device can include providing a reel-type tension device that includes a housing, a spool rotatably disposed within the housing, a knob member operably coupled to the spool to rotate the spool in a first direction within the housing to wind a tension member around the spool, and a load holding mechanism coupled to the spool and configured to allow rotation of the spool in the first direction within the housing and to prevent rotation of the spool in a second direction within the housing and to prevent the tension member from being unwound from around the spool. The method can also include coupling an audible component to the reel-type tension device, the audible component being configured to generate an audible noise in response to operation of the knob member to indicate adjustment of the tension member. The method can also include adjusting the audible component that adjusts the audible noise generated by the audible component.

[0065]

[0081] The load holding mechanism may not generate audible noise detectable by the human ear. The audible component may be configured to generate audible noise in response to applying tension to the tension member and to generate audible noise in response to relaxing the tension member. The audible noise generated in response to applying tension to the tension member may be different from the audible noise generated in response to relaxing the tension member. The audible component may include a pawl member or a beam that engages with the housing to generate audible noise. The pawl member or beam may not be able to prevent rotation of the spool within the housing when a significant rotational force is applied to the spool via the tension member or knob member. The load holding mechanism of the reel type tension device may not include a pawl member or a beam.

[0066]

[0082] In some cases, it may be beneficial to form the components of the reel system 100 directly on the fabric material such that the fabric is integrally formed with or incorporated within the components. In some embodiments, the fabric material may facilitate attaching the components to an article, such as attaching the components to a shoe. In certain embodiments, the components may be formed on the fabric material by insert molding in which the fabric material is placed within a mold or die and a polymer material is injected over or through the fabric material. The component of the reel system may be a first component that includes an upper end, a lower end, and an internal cavity in which a second component of the reel type tension system may be disposed. Specific examples of the first component may be a base member or a bayonet configured to couple with the housing of the reel system. Another example of the first component may be a housing configured to couple with the spool and other components of the system described herein. Yet another example of the first component may be a guide member that includes an internal cavity configured to receive the tension member of the reel system to guide the tension member around the path of the article.

[0067]

[0083] When a component is formed on a fabric material, the fabric material may be disposed near the lower end of the component and extend laterally from at least a portion of the outer periphery of the component, and more generally around the entire outer periphery of the component. The fabric material can be integrally bonded to the first component by injecting the polymer material (i.e., thermoplastic or thermosetting material) of the component through the fabric material, so that the polymer material of at least a part of the component saturates or impregnates through the fabric material and extends axially downward from the bottom surface of the fabric material and axially upward from the upper surface of the fabric material. In some embodiments, the polymer material may be saturated or impregnated through the fabric material such that the entire lower end of the component extends axially downward from the bottom surface of the fabric material and axially upward from the upper surface of the fabric material. In such embodiments, the polymer material at the lower end of the component may form an annular ring on the bottom surface of the fabric material. In other embodiments, only a part of the lower end extends axially above and below the fabric material, and the remaining part of the lower end may be located only on one side of the fabric material.

[0068]

[0084] Referring now to FIGS. 15, 17-19, and 23-25, a base member 220 attached to a piece of woven fabric material such as fabric 200 is shown. The fabric can be essentially any fabric, such as a polymer-based fabric. In a particular embodiment, the fabric may be a 500-denier polyester fabric. FIG. 17 shows the base member 220 not attached to the fabric 200, and FIG. 18 shows a perspective view of the base member 220 attached to the fabric 200. As shown in FIG. 18, after the base member 220 is attached to the fabric 200, the fabric 200 is in a substantially coplanar plane with the bottom surface of the base member 220. The fabric 200 extends laterally from at least a portion of the outer periphery of the base member 220, and more generally, around the entire outer periphery of the base member 220. FIGS. 15 and 24 show bottom views of the fabric 200 and the base member 220, showing alternative attachment configurations of the base member 220 and the fabric 200. FIG. 23 shows a bottom view of an embodiment of the fabric 200 before the base member 220 is formed on the fabric 200. FIG. 19 shows a cross-sectional view of an embodiment of the attached base member 220 and the fabric 200.

[0069]

[0085] In an exemplary embodiment, the base member 220 is directly injected into the fabric 200. This is achieved by insert molding or injecting the material of the base member 220 through the bottom surface of the fabric 200, resulting in a very high adhesive strength and preventing or minimizing the separation of the base member 220 from the fabric 200. For example, when the material of the base member is directly injected through the bottom surface of the fabric 200, it may be possible to withstand a force of 50 Kg before the material begins to separate. Since the material of the base member 220 is typically a polymeric material (i.e., a thermoplastic or thermosetting material) injected through the fabric 200, when the base member 220 is formed, the fabric 200 is disposed within at least a portion of the base member 220, so that the polymeric material is disposed on both sides of the fabric 200. The placement of the fabric 200 within the base member 220 is shown in FIGS. 15, 19, and 24.

[0070]

[0086] As shown in FIG. 17, the base member 220 may be a component of a system that includes an internal cavity configured to receive and releasably couple the housing 102 as shown in FIG. 16. In other embodiments, the base member may be a housing component as shown in FIG. 16, and may be directly injected into the fabric 200 and formed integrally with the fabric 200. In such embodiments, the need for separate base member 220 and housing 102 can be eliminated, and these components can be integrated into a single component that is integrally coupled with the fabric 200. The housing component may include a race port 104 in which a tension member or cord is disposed.

[0071]

[0087] In some cases, the material of the base member may be injected into the fabric 200 to change the saturation or integration of the material within the fabric 200. The term saturation or integration of the material of the base member within the fabric 200 refers to the amount of the material of the base member that remains disposed within the fabric 200 after the injection process. When the material of the base member is highly saturated / integrated within the fabric 200, the injected base member material is essentially disposed on both sides of the fabric 200 and through the interior of the fabric. When the saturation / integration of the material of the base member within the fabric 200 is low, the injected base member material does not completely penetrate the fabric 200 or is essentially disposed on one side of the fabric 200. The fabric is more visible in regions where the saturation / integration of the material of the base member within the fabric 200 is low. In certain embodiments, the material of the base member is glass-filled polypropylene and / or copolyester.

[0072]

[0088] In one embodiment, the saturation / integration of the material of the base member varies between segments or portions of the base member, such that the material of the base member is highly saturated / integrated through the fabric 200 in one segment or portion of the base member and has low saturation / integration through the fabric 200 in another segment or portion of the base member. In such an embodiment, the change in the material of the base member within the fabric 200 is indicated by the cross-hatching or shaded regions of FIGS. 15 and 19. The cross-hatching or shaded regions represent portions of the fabric 200 where the material of the base member is saturated or integrated by the fabric 200. Since the material of the base member is concentrated in these regions and is visible from the bottom surface of the fabric 200, these regions may appear dark or may appear to be a slightly different color. The change in the saturation / integration of the material of the base member can be designed to provide desirable characteristics such as an increase in the bonding or adhesion strength between the two materials, an increase in the strength of the base member, and the like.

[0073]

[0089] The strength of the bond or adhesion between the fabric 200 and the base member 220 can be substantially increased when the material of the base member is highly saturated / integrated within the fabric 200. However, since there is less material within the base member, when the material of the base member is highly saturated / integrated within the fabric 200, the strength of the base member 220 itself may decrease. A decrease in the strength of the base member 220 can adversely affect the way the base member 220 interacts with other components of the system such as the housing 102. For example, the wall 224 on the opposite side of the front tab 222 may be a thinner portion of the material in order to reduce the size and / or weight of the base member 220. If the base member 220 is too thin near the wall 224, the wall 224 may crack or break from the pressure or force applied to the wall 224 by the housing 102. Therefore, it may be desirable to construct the base member 220 and the fabric 200 such that while an increase in the bonding / adhesion between these materials is achieved due to the saturation of the material of the base member within the fabric 200, the wall 224 remains relatively strongly reinforced.

[0074]

[0090] In some cases, the base member 220 may be subject to a greater external force near the front tab 222. The external force may peel or cause peeling of the base member 220 from the fabric 200, and thus an increase in the bonding / adhesion strength near the front tab 222 may be desirable. The wall 224 may mainly be used to couple the base member 220 to the housing 102, and thus it may be more desirable to reinforce or strengthen the base member 220 adjacent to the wall 224. This increased bonding / adhesion strength near the front tab 222 and the further strengthening of the base member 220 near the wall 224 may be achieved by increasing the saturation / integration of the material of the base member near the front tab 222 while decreasing the saturation / integration of the material of the base member near the wall 224, as shown in FIGS. 15 and 19.

[0075]

[0091] In one embodiment, the amount of saturation / integration of the material of the base member within the fabric 200 can be controlled based on the arrangement of the injection holes 226 through which the material of the base member is injected through the fabric 200. The material of the base member may saturate / integrate more completely into the fabric 200 around the injection holes 226, and thus the injection holes 226 may be arranged adjacent to the regions of the base member 220 where it is desired to increase the bonding / adhesion strength, and may not be arranged in the regions where it is desired to increase the strength of the component. FIGS. 15 and 19 show injection holes 226 arranged near the front tab 222, where cross-hatching or shading is shown and typically an increase in the saturation / integration of the material of the base member and the fabric 200 is desired. In this way, the hole pattern can be designed to provide a designed combination of desired strengths without compromising the integrity of the component.

[0076]

[0092] In another embodiment, the saturation / integration of the base member material may be relatively uniform with respect to the base member such that the base member material is highly saturated / integrated through the fabric 200 or slightly saturated / integrated through the fabric 200. FIG. 24 shows a bottom view of the fabric 200 showing uniform saturation / integration of the polymer material through the fabric. In FIG. 24, the base member material is highly saturated / integrated through the fabric 200 such that the fabric 200 is disposed within the polymer material essentially across the entire lower end of the base member 220. The description of the fabric 200 being disposed within the polymer material of the base member 220 means that the polymer material is disposed or positioned on both sides of the fabric 200. Since the base member 220 has an essentially cylindrical configuration (i.e., circular lower end and hollow interior) as shown in FIG. 17, the placement of the polymer material on both sides of the fabric 200 forms an annular ring 223 on the bottom surface of the fabric 200 as shown in FIG. 24. If the lower end of the base member 220 has a different configuration (e.g., planar, elliptical, etc.), the shape formed on the bottom surface of the fabric 200 will correspond to the shape of the lower end of the base member 220.

[0077]

[0093] As shown in FIG. 25, in some embodiments, the base member 220 includes one or more thinner material sections 225. Since the fabric 200 is disposed or positioned within the base member material, the fabric 200 can be seen on the upper surface of the thinner material section 225 of the base member 220. FIG. 23 shows a view of the fabric 200 before the base member material is injected through the fabric 200. The fabric 200 includes injection holes 226 arranged to promote saturation / integration of the polymer material through the fabric 200 to form the annular ring 223 shown in FIG. 24. FIG. 23 also shows that the fabric 200 includes a plurality of tabs 240 that extend laterally outward from the body of the fabric 200. One or more of the tabs 240 may include an opening 241 as shown.

[0078]

[0094] The changes in material saturation / integration within the fabric 200 are shown with respect to the base member 220, but it should be understood that other components of the system, such as guide members for the tension members and other components, can likewise be directly injected into the fabric. Thus, the general description above is with respect to components of any reel system and not particularly with respect to the base member.

[0079]

[0095] A method of forming components of a reel - type tension system can include providing a fabric material and disposing the fabric material within a die or mold. The method can also include injecting a polymer material through the fabric material such that the polymer material fills a void or space within the die or mold that defines the shape of a first component of the reel - type tension system. The method can also include cooling the polymer material such that the polymer material cures to form the first component of the reel - type tension system. Since at least a portion of the polymer material of the first component is saturated or impregnated through the fabric material, the polymer material of the first component extends axially downward below the bottom surface of the fabric material and axially upward above the top surface of the fabric material. The fabric material may be disposed within the lower end of the die or mold such that the polymer material is injected through the fabric material from the lower end of the die or mold toward the upper end of the die or mold. The lower end of the die or mold may correspond to the lower end of the first component. The polymer material is injected and cooled through the fabric material so as to saturate or impregnate the polymer material of the entire lower end of the first component through the fabric material. In such a case, the polymer material of the entire bottom may extend axially downward below the bottom surface of the fabric material and axially upward above the top surface of the fabric material. The polymer material is injected and cooled through the fabric material such that the polymer material forms an annular ring on top of the bottom surface of the fabric material. The polymer material may comprise or consist of a glass - filled polypropylene material, a copolyester material, or a combination thereof. The polymer material is injected and cooled through the fabric material such that the polymer material is visible from the top surface of a fairly thin section or segment of the first component.

[0080]

[0096] Next, referring to FIG. 20, a stop code or mechanism 230 attached to the spool 140 and the housing 102 is shown. The stop code 230 is wound around a stop code channel 232 that is separate from the annular channel 144. As the tension member is rewound from the annular channel 144, the stop code 230 is wound around the stop code channel 232 such that the stop code 230 wraps around the stop code channel 232. The lengths and arrangements of the stop code 230 and the stop code channel 232 are such that when the tension member is completely or almost completely rewound from the annular channel 144, the stop code 230 wraps almost or completely around the stop code channel 232, thereby preventing further rotation of the spool 140 within the internal region 116 of the housing 102. In this way, the stop code 230 prevents the reverse winding of the tension member around the annular channel 144, i.e., the winding of the tension member around the annular channel 144 when the spool rotates in the unwinding direction. The function and arrangement of the stop code are further described in U.S. Patent No. 9,259,056, filed on June 21, 2013, and entitled "Reel-Type Racing System", the entire disclosure of which is incorporated herein by reference.

[0081]

[0097] To attach the stop code 230 to the reel system 100, the proximal end of the stop code 230 is inserted through the coupling opening 108 of the housing, and a knot is tied to the proximal end of the stop code 230. The knot engages with the coupling opening 108 to prevent the proximal end of the stop code 230 from being pulled through the coupling opening 108. The distal end of the stop code 230 is similarly inserted through a pair of openings (not shown) in the spool 140, and a knot is tied to the distal end of the stop code 230. The knot engages with the uppermost opening (not shown) to prevent the distal end of the stop code 230 from being pulled through the spool 140. When the knot at the distal end of the stop code 230 engages with the opening of the spool, the knot is positioned within the slot 109 of the spool 140. In some cases, a small portion of the stop code 230 extends across the annular channel 144 of the spool. In such cases, a tension member (not shown) is wrapped around the stop code 230.

[0082]

[0098] Figures 21 - 22 show alternative embodiments of the coil spring 400 and the release hub assembly. Specifically, the coil spring 400 is configured to be disposed within the upper hub 326 and the lower hub 322. The outer diameter of the coil spring 400 is approximately the same size or slightly larger than the inner diameters of the upper hub 326 and the lower hub 322, so that the spring 400 bends outwardly and frictionally engages with the upper hub 326 and the lower hub 322, locking the two hubs together in a manner similar to the method described herein. As shown in Figure 22, the lower hub 322 is fixed to the housing of the reel system 500 via axially extending teeth 324, while the upper hub 326 is fixed to the spool of the reel system 500 via axially extending teeth 328. When the upper hub 326 and the lower hub 322 are locked together, rotation of the upper hub 326 relative to the lower hub 322 is prevented, thereby locking the spool in place relative to the housing.

[0083]

[0099] To unlock the upper hub 326 from the lower hub 322, the diameter of the coil spring 400 is reduced. The coil spring 400 includes a tang 402 that extends radially inward and engages a component of a release sleeve (not shown) or a knob. When the knob is rotated in the loosening direction, the tang 402 engages through the release sleeve or a component of the knob, causing the coil spring to be wound in a direction in which the coil spring contracts or moves radially inward (i.e., the counterclockwise direction of the spring shown in FIG. 21). As the coil spring 400 moves in this way, the outer diameter of the coil spring decreases until the upper hub 326 is unlocked from the lower hub 322 and can rotate relative to the lower hub 322, and the spool can rotate in a direction to loosen within the housing.

[0084]

[0100] The upper hub 326 and the lower hub 322 may have different inner diameters, may be made of different materials, and / or may have different surface finishes to ensure that the coil spring 400 can rotate around one hub while remaining fixed to the other hub as desired. If a release sleeve is used, the release sleeve may be a cylindrical sleeve that fits completely inside the coil spring 400 in a way that minimizes the frictional engagement between the release sleeve and the coil spring 400. Additionally, although the tang 402 is shown disposed near the outer end of the upper hub 326, in other embodiments, the tang 402 may be disposed adjacent to the outer end of the lower hub 322.

[0085]

[0101] Although some embodiments and arrangements of various components have been described herein, it should be understood that the various components and / or combinations of components described in the various embodiments can be modified, rearranged, changed, adjusted, etc. For example, the arrangement of any of the components of the described embodiments can be adjusted or rearranged, and / or the various components described can be used in any of the embodiments not currently described or used. Accordingly, it should be understood that the various embodiments are not limited to the specific arrangements and / or component structures described herein.

[0086]

[0102] In addition, it should be understood that the executable combinations of the features and elements disclosed herein are also considered to be disclosed. Further, whenever features are not discussed with respect to an embodiment of the present disclosure, it should be noted that for those skilled in the art, some embodiments of the present invention implicitly and specifically exclude such features, thereby providing support for negative claim limitations.

[0087]

[0103] Although some embodiments have been described, those skilled in the art will recognize that various modifications, alternative configurations, and equivalents can be used without departing from the spirit of the present invention. Further, many well-known processes and elements have not been described in order to avoid unnecessarily obscuring the present invention. Accordingly, the above description should not be construed as limiting the scope of the present invention.

[0088]

[0104] When a range of values is provided, it is understood that each intervening value, to the tenth of the unit of the lower limit value, between the upper and lower limit values of that range is specifically disclosed, unless the context clearly dictates otherwise. Each smaller range between a defined value or intervening value within the defined range and another defined value or intervening value within that defined range is encompassed. The upper and lower limit values of these smaller ranges may independently be included in or excluded from the range, and each range in which either, neither, or both of the limiting values are included in the smaller range is also included in the invention, subject to specifically excluded limiting values within the defined range. When one or both of the limiting values are included in the defined range, ranges excluding either or both of the included limiting values are also included.

[0089]

[0105] As used in this specification and the appended claims, the singular forms "a", "an", and "the" include plural referents unless the context clearly dictates otherwise. Thus, for example, reference to "a process" includes a plurality of such processes, reference to "the device" includes reference to one or more devices known to those of ordinary skill in the art and their equivalents, and the like.

[0090]

[0106] Also, as used in this specification and the appended claims, the words "comprise", "comprising", "include", "including", and "includes" are intended to specify the presence of the stated feature, integer, component, or step, but do not preclude the presence or addition of one or more other features, integers, components, steps, acts, or groups.

Claims

1. a housing having an interior region; a spool rotatably disposed within the interior region of the housing; a knob operatively coupled to the spool for rotating the spool in a first direction within the interior region of the housing to wrap a tension member around the spool, thereby tensioning the tension member; an audio component configured to generate an audible noise in response to tensioning the tensioning member and to generate an audible noise in response to releasing the tensioning member, thereby providing audible indication of an adjustment to the tensioning member tension; A tensioning device having:

2. The tensioning device of claim 1 , wherein the audible noise responsive to tensioning the tensioning member is different from the audible noise responsive to releasing the tensioning member.

3. 10. The tensioning device of claim 1, wherein the audible noise responsive to tensioning the tensioning member is essentially uniform with the audible noise responsive to releasing the tensioning member.

4. The tensioning device of claim 1 , wherein the audible component includes at least one pawl member or beam that engages teeth on the housing to produce the audible noise.

5. The tensioning device of claim 1 , wherein the audio component is capable of adjusting the audible noise produced by the audio component.

6. 10. The tensioning device of claim 1, wherein the audible component is configured not to interfere with rotation of the spool within the housing when a rotational force is applied to the spool via the tensioning member or the knob.

7. 10. The tensioning device of claim 1, further comprising a load retention mechanism separate from the audio component and coupled to the spool, the load retention mechanism configured to allow rotation of the spool in the first direction within the interior region of the housing, prevent rotation of the spool in a second direction within the interior region of the housing, and prevent unwinding of the tension member from around the spool.

8. Housing and a spool rotatably disposed within the housing; a knob operably coupled to the spool for rotating the spool in a first direction within the housing; a pawl member engaging the teeth to generate an audible noise in response to rotation of the knob in the first direction and to generate an audible noise in response to rotation of the knob in a second direction; A tensioning device having:

9. 9. The tensioning device of claim 8, wherein the audible noise responsive to rotation of the knob in the first direction is different from the audible noise responsive to rotation of the knob in the second direction.

10. 9. The tensioning device of claim 8, wherein the audible noise responsive to rotation of the knob in the first direction is essentially uniform with the audible noise responsive to rotation of the knob in the second direction.

11. The tensioning device of claim 8 , wherein the pawl member is capable of adjusting the audible noise produced by the pawl member.

12. The tensioning device of claim 8 , wherein the teeth are disposed on an interior surface or region of the housing.

13. 9. The tensioning device of claim 8, wherein the pawl member is configured to deflect in and out of adjacent teeth to produce an audible clicking sound in response to rotation of the knob in the first direction and in response to rotation of the knob in the second direction.

14. 9. The tensioning device of claim 8, further comprising a load retention mechanism coupled to the spool and configured to allow rotation of the spool within the housing in the first direction and prevent rotation of the spool within the housing in the second direction.

15. Housing and a spool rotatably disposed within the housing; a knob operatively coupled to the spool for rotating the spool in a first direction within the housing to wrap a tension member around the spool, thereby tensioning the tension member; a pawl member configured to generate an audible noise in response to tensioning the tensioning member and to generate an audible noise in response to releasing the tensioning member, thereby providing an audible indication of an adjustment of tension in the tensioning member; A tensioning device having:

16. 16. The tensioning device of claim 15, wherein the audible noise responsive to tensioning the tensioning member is different from the audible noise responsive to releasing the tensioning member.

17. 16. The tensioning device of claim 15, wherein the audible noise responsive to tensioning the tensioning member is essentially uniform with the audible noise responsive to releasing the tensioning member.

18. 16. The tensioning device of claim 15, wherein the pawl member is engageable with teeth disposed on an interior surface or region of the housing.

19. 20. The tensioning device of claim 18, wherein the pawl members are configured to deflect in and out of adjacent teeth to produce audible clicking sounds in response to tensioning the tensioning member and in response to releasing the tensioning member.

20. 16. The tensioning device of claim 15, further comprising a load retention mechanism coupled to the spool and configured to allow rotation of the spool within the housing in the first direction and prevent rotation of the spool within the housing in a second direction.

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