Integrated closure device component and method

Abstract

To provide a closure system with the reduced number of the whole parts and / or components.SOLUTION: According to an embodiment, a method of assembling a reel includes a step for coupling a drive component with a tightening component and a step for coupling the tightening component with a top end of a housing. A spool component is then inserted within a bottom end of the housing so that the spool component is positioned within the housing's interior region and faces a bottom surface of the drive component. An attachment component is then coupled with the bottom end of the housing. The attachment component includes a coupling member that couples with the drive component. Coupling of the coupling member with the drive component operationally couples the drive component and the spool component so that operation of the tightening component causes the spool component to rotate within the housing in a first direction while preventing rotation of the spool component in a second direction.SELECTED DRAWING: Figure 12A

Description

[Background technology]

[0001] Background of the Invention The present invention relates to closure devices for various articles, such as braces, medical devices, shoes, garments, apparel, and the like. Such articles typically include a closure device that allows the article to be placed and closed around a body part. Closure devices are typically used to maintain or secure the article to a body part. For example, a shoe is typically placed on an individual's foot, and laces are pulled and tightened to close the shoe around the foot and secure the shoe to the foot. Conventional closure devices have been improved in an effort to enhance the fit and / or comfort of the article around a body part. For example, shoe lacing configurations and / or patterns have been improved in an effort to enhance the fit and / or comfort of shoe wear. Conventional closure devices have also been improved in an effort to reduce the time required to close and secure the article around a body part. These improvements have led to the use of various pull cords, straps, and tensioning devices that allow the article to be quickly closed and secured to the foot. Summary of the Invention

[0002] Brief Summary of the Invention Embodiments described herein provide closure systems with a reduced overall number of parts and / or components. The closure systems can be used to close and / or fasten a variety of articles, such as shoes, braces, apparel, sports equipment, and the like. The reduced number of parts or components lowers the overall cost of the system and / or allows for easier assembly of the system. According to one aspect, a reel assembly for fastening an article is provided. The reel assembly includes a housing component including an interior region. A spool component is rotatably disposed within the interior region of the housing component. The spool includes an annular channel around which tension members for fastening the article are gathered. A drive component is disposed axially above and operably coupled to the spool component. The drive component allows the spool component to rotate in a first direction within the interior region of the housing component while preventing rotation of the spool component in a second direction.

[0003] A clamping component is rotatably coupled within the housing and is disposed axially above and coupled to the drive component. Operation of the clamping component causes the spool component to rotate in a first direction within the interior region of the housing component, gathering the tension member around the annular channel of the spool component, thereby clamping the article. An attachment component is disposed axially below the spool component. The attachment component includes a coupling member that protrudes axially upward into the interior region of the housing component and couples the attachment component to the drive component. The reel assembly includes six or fewer separate components. In some embodiments, the reel assembly includes five or fewer separate components. One or more of the components of the reel assembly may be assembled together by a snap fit such that the reel assembly does not include screws, rivets, or other rigid fasteners.

[0004] In some embodiments, the tightening component includes a body and a gripping body disposed on a periphery of the body. The gripping body has a greater coefficient of friction than the body to allow a user to easily grasp and manipulate the tightening component. In some embodiments, the tightening component is axially movable relative to the housing component to disengage the drive component from the spool component, thereby allowing the spool component to rotate in a second direction, thereby loosening the article. In some embodiments, the reel assembly may also include an attachment component that is coupleable with the article and releasably coupleable with the reel assembly. The attachment component may include an attachment mechanism configured for releasable coupling with the reel assembly and an attachment mechanism configured for coupling with the article. The attachment mechanism may be made of a first material, and the attachment mechanism may be made of a second material that is softer than the first material.

[0005] In some embodiments, the drive component includes teeth that engage with corresponding teeth on a housing component or clutch component (e.g., a separate disk or component) to allow the spool component to rotate in a first direction while preventing rotation in a second direction. The drive component includes one or more tabs disposed on a top surface of the drive component. The one or more tabs are configured to move the teeth of the drive component axially upward when the drive component is moved axially upward, disengaging the teeth of the drive component from corresponding teeth on the housing component or clutch component. The clutch component can be a component that mates with the spool component, housing component, or clamping component and includes teeth that axially or radially engage with the teeth of the drive component. The drive component can be moved axially upward by a user pulling a clamping component (e.g., a knob) axially upward, by a user manipulating the clamping component (e.g., rotating a knob counterclockwise), by a user pressing a button or selection, etc.

[0006] According to another aspect, a reel assembly for fastening an article is provided. The reel assembly includes a housing having an interior region, an open upper end, and an open lower end. A spool is rotatably disposed within the interior region of the housing. The spool is configured to gather a tension member around it to fasten the article. A drive component is disposed axially above the spool and operably coupled thereto to allow the spool to rotate in a first direction within the interior region of the housing while preventing rotation of the spool in a second direction. A clamping component is disposed axially above and coupled thereto such that operation of the clamping component causes the spool to rotate in the first direction within the interior region of the housing to gather the tension member around the spool, thereby fastening the article. When the reel assembly is assembled, the spool is disposed substantially within the interior region and is accessible from the open lower end of the housing, allowing a user to couple the tension member to the spool.

[0007] In some embodiments, the reel assembly also includes an attachment piece disposed axially below the spool. The attachment piece includes a coupling member that projects axially upward into an interior region of the housing and couples with the drive piece. In some embodiments, the housing may also include a divider configured to contact an upper surface of the spool to prevent the spool from moving axially upward within the housing.

[0008] In some embodiments, the drive piece can be axially movable to disengage from the spool piece, thereby allowing the spool piece to rotate in a second direction. The drive piece can be axially movable by rotation of the clamp piece in the second direction, or by axial movement of the clamp piece relative to the housing. In some embodiments, the tension member can be integrally formed from the housing by stretching and deforming the material of the housing.

[0009] According to another aspect, a method for assembling a reel assembly is provided. The method includes coupling a drive piece to a clamping piece and coupling the clamping piece to an upper end of the housing such that the drive piece faces an interior region of the housing. The method also includes inserting a spool piece into a lower end of the housing such that the spool piece is disposed within the interior region of the housing and such that the upper end of the spool piece faces a lower surface of the drive piece. The method further includes coupling an attachment piece to the lower end of the housing. The attachment piece includes a coupling member that couples with the drive piece. The coupling member and the drive piece operatively couple the drive piece to the spool piece such that operation of the clamping piece permits rotation of the spool piece within the housing in a first direction while preventing rotation of the spool piece in a second direction.

[0010] In some embodiments, assembling the reel assembly includes coupling the components together such that the reel assembly does not include screws or other rigid fasteners. In some embodiments, coupling the drive component with the clamping component includes snapping the drive component into a recessed portion of the clamping component. In some embodiments, coupling the clamping component with the upper end of the housing includes snapping a lip of the clamping component over a corresponding lip of the housing. In some embodiments, coupling the attachment component with the lower end of the housing includes snapping a flange of the attachment component into an opening in the housing. In some embodiments, the method further includes snapping a coupling member of the attachment component into an opening in the drive component to couple the components together. In some embodiments, the assembled reel assembly may be coupled to a mounting component disposed on an article to be clamped by the reel assembly.

[0011] According to another aspect, a reel assembly for fastening articles is provided. The reel assembly includes a housing having an interior region and a partition dividing the interior region into an upper portion and a lower portion. A spool is rotatably disposed within the lower portion of the interior region of the housing, axially below the partition. The partition prevents the spool from moving axially upward into the upper portion. A drive component is disposed within the upper portion of the interior region of the housing. The drive component is axially movable relative to the spool between an engaged state and a disengaged state. In the engaged state, the drive component allows the spool to rotate in a first direction within the interior region of the housing while preventing the spool component from rotating in a second direction. In the disengaged state, the drive component allows the spool to rotate in the second direction within the interior region of the housing.

[0012] A clamping piece is disposed axially above and coupled to the drive piece such that operation of the clamping piece rotates the spool in a first direction within the interior region of the housing. An attachment piece is disposed axially below the spool. The attachment piece includes a coupling member that projects axially upward into the interior region of the housing and couples with the drive piece.

[0013] According to another aspect, an integrated tightening device and lacing system is provided. The integrated device and system includes a base portion and a tension member having a proximal end integrally formed with the base portion and a distal end opposite the proximal end. The tension member is formed by stretching and deforming a material of the base portion. The integrated device and system also includes a spool coupled to the distal end of the tension member. The spool is configured to gather the tension member to tighten an article. The integrated device and system further includes a tightening element operatively coupled to the spool such that operation of the tightening element causes the spool to gather the tension member, thereby tightening the article.

[0014] In some embodiments, the ends of the tension members include gripping features that facilitate elongation of the material of the base portion, hi some embodiments, the material of the base portion is deformable only when the material is above a threshold temperature.

[0015] According to another aspect, a method of forming a lacing system is provided. The method includes the steps of securing a base portion of material and stretching the base portion of material to form a tension member having a proximal end integrally attached to the base portion and a distal end opposite the proximal end. The method also includes coupling the distal end of the tension member to a spool. The spool is configured to gather the tension member and fasten the article. The method further includes operatively coupling the spool to the fastening element such that operation of the fastening element causes the spool to gather the tension member, thereby fastening the article.

[0016] In some embodiments, securing the material of the base portion includes gripping a grip feature of the base portion, the grip feature facilitating elongation of the material of the base portion, and in some embodiments, the method further includes elongating the material when the material of the base portion is above a threshold temperature. [Brief explanation of the drawings]

[0017] The present invention will now be described in conjunction with the accompanying drawings.

[0018] [Figure 1] 1 shows a perspective view of a lacing system that may be used to fasten a shoe or other item. [Figure 2] 1 shows a perspective view of another lacing system that can be used to fasten a shoe or other article. [Figure 3] 3 shows an exploded perspective view of the lacing system of FIG. 2. FIG. [Figure 4] 3 shows an exploded perspective view of the lacing system of FIG. 2. FIG. [Figure 5A] 1 shows the gripped cover and core of the reel assembly snapped together into the assembly. [Figure 5B] 1 shows the gripped cover and core of the reel assembly snapped together into the assembly. [Figure 5C] 5B shows an exploded perspective view of the cover with grip and core of FIG. 5A. [Figure 6A] 1 illustrates an embodiment of a reel assembly having several integrated parts. [Figure 6B] 1 illustrates an embodiment of a reel assembly having several integrated parts. [Figure 6C] 1 illustrates an embodiment of a reel assembly having several integrated parts. [Figure 6D] 1 illustrates an embodiment of a reel assembly having several integrated parts. [Figure 6E] 1 illustrates an embodiment of a reel assembly having several integrated parts. [Figure 6F] 1 illustrates an embodiment of a reel assembly having several integrated parts. [Figure 6G] 1 illustrates an embodiment of a reel assembly having several integrated parts. [Figure 6H] 1 illustrates an embodiment of a reel assembly having several integrated parts. [Figure 6I] 1 illustrates an embodiment of a reel assembly having several integrated parts. [Figure 6J] 1 illustrates an embodiment of a reel assembly having several integrated parts. [Figure 6K] 1 illustrates an embodiment of a reel assembly having several integrated parts. [Figure 7A] 10 shows another embodiment of a reel assembly having several integrated parts. [Figure 7B] 10 shows another embodiment of a reel assembly having several integrated parts. [Figure 7C] 10 shows another embodiment of a reel assembly having several integrated parts. [Figure 8A]10 illustrates yet another embodiment of a reel assembly having several integrated parts. [Figure 8B] 10 illustrates yet another embodiment of a reel assembly having several integrated parts. [Figure 8C] 10 illustrates yet another embodiment of a reel assembly having several integrated parts. [Figure 8D] 10 illustrates yet another embodiment of a reel assembly having several integrated parts. [Figure 8E] 10 illustrates yet another embodiment of a reel assembly having several integrated parts. [Figure 8F] 10 illustrates yet another embodiment of a reel assembly having several integrated parts. [Figure 8G] 10 illustrates yet another embodiment of a reel assembly having several integrated parts. [Figure 8H] 10 illustrates yet another embodiment of a reel assembly having several integrated parts. [Figure 8I] 10 illustrates yet another embodiment of a reel assembly having several integrated parts. [Figure 8J] 10 illustrates yet another embodiment of a reel assembly having several integrated parts. [Figure 8K] 10 illustrates yet another embodiment of a reel assembly having several integrated parts. [Figure 8L] 10 illustrates yet another embodiment of a reel assembly having several integrated parts. [Figure 9A] 10 illustrates various other aspects of a reel assembly having integrated components and various reel assembly components. [Figure 9B] 10 illustrates various other aspects of a reel assembly having integrated components and various reel assembly components. [Figure 9C] 10 illustrates various other aspects of a reel assembly having integrated components and various reel assembly components. [Figure 9D]10 illustrates various other aspects of a reel assembly having integrated components and various reel assembly components. [Figure 9E] 10 illustrates various other aspects of a reel assembly having integrated components and various reel assembly components. [Figure 9F] 10 illustrates various other aspects of a reel assembly having integrated components and various reel assembly components. [Figure 9G] 10 illustrates various other aspects of a reel assembly having integrated components and various reel assembly components. [Figure 9H] 10 illustrates various other aspects of a reel assembly having integrated components and various reel assembly components. [Figure 9I] 10 illustrates various other aspects of a reel assembly having integrated components and various reel assembly components. [Figure 9J] 10 illustrates various other aspects of a reel assembly having integrated components and various reel assembly components. [Figure 9K] 10 illustrates various other aspects of a reel assembly having integrated components and various reel assembly components. [Figure 9L] 10 illustrates various other aspects of a reel assembly having integrated components and various reel assembly components. [Figure 9M] 10 illustrates various other aspects of a reel assembly having integrated components and various reel assembly components. [Figure 9N] 10 illustrates various other aspects of a reel assembly having integrated components and various reel assembly components. [Figure 9O] 10 illustrates various other aspects of a reel assembly having integrated components and various reel assembly components. [Figure 10A] 10 illustrates an embodiment of a spool housing that can be coupled with multiple bayonets. [Figure 10B] 10 illustrates an embodiment of a spool housing that can be coupled with multiple bayonets. [Figure 10C]10 illustrates how the race may be coupled to the spool housing to facilitate easy race installation and / or replacement. [Figure 10D] 10 illustrates how the race may be coupled to the spool housing to facilitate easy race installation and / or replacement. [Figure 10E] 10 illustrates how the race may be coupled to the spool housing to facilitate easy race installation and / or replacement. [Figure 10F] 10 illustrates how the race may be coupled to the spool housing to facilitate easy race installation and / or replacement. [Figure 10G] 10 illustrates how the race may be coupled to the spool housing to facilitate easy race installation and / or replacement. [Figure 10H] 10 illustrates how the race may be coupled to the spool housing to facilitate easy race installation and / or replacement. [Figure 11A] 10 illustrates another embodiment of a reel assembly having various integrated components. [Figure 11B] 10 illustrates another embodiment of a reel assembly having various integrated components. [Figure 11C] 10 illustrates another embodiment of a reel assembly having various integrated components. [Figure 11D] 10 illustrates another embodiment of a reel assembly having various integrated components. [Figure 11E] 10 illustrates another embodiment of a reel assembly having various integrated components. [Figure 11F] 10 illustrates another embodiment of a reel assembly having various integrated components. [Figure 11G] 10 illustrates another embodiment of a reel assembly having various integrated components. [Figure 11H] 10 illustrates another embodiment of a reel assembly having various integrated components. [Figure 11I] 10 illustrates another embodiment of a reel assembly having various integrated components. [Figure 11J]10 illustrates another embodiment of a reel assembly having various integrated components. [Figure 11K] 10 illustrates another embodiment of a reel assembly having various integrated components. [Figure 11L] 10 illustrates another embodiment of a reel assembly having various integrated components. [Figure 11M] 10 illustrates another embodiment of a reel assembly having various integrated components. [Figure 11N] 10 illustrates another embodiment of a reel assembly having various integrated components. [Figure 11O] 10 illustrates another embodiment of a reel assembly having various integrated components. [Figure 11P] 10 illustrates another embodiment of a reel assembly having various integrated components. [Figure 12A] 10 illustrates another embodiment of a reel assembly having various integrated components. [Figure 12B] 10 illustrates another embodiment of a reel assembly having various integrated components. [Figure 12C] 10 illustrates another embodiment of a reel assembly having various integrated components. [Figure 12D] 10 illustrates another embodiment of a reel assembly having various integrated components. [Figure 12E] 10 illustrates another embodiment of a reel assembly having various integrated components. [Figure 12F] 10 illustrates another embodiment of a reel assembly having various integrated components. [Figure 12G] 10 illustrates another embodiment of a reel assembly having various integrated components. [Figure 12H] 10 illustrates another embodiment of a reel assembly having various integrated components. [Figure 12I] 10 illustrates another embodiment of a reel assembly having various integrated components. [Figure 12J] 10 illustrates another embodiment of a reel assembly having various integrated components. [Figure 12K]10 illustrates another embodiment of a reel assembly having various integrated components. [Figure 12L] 10 illustrates another embodiment of a reel assembly having various integrated components. [Figure 12M] 10 illustrates another embodiment of a reel assembly having various integrated components. [Figure 12N] 10 illustrates another embodiment of a reel assembly having various integrated components. [Figure 12O] 10 illustrates another embodiment of a reel assembly having various integrated components.

[0019] In the accompanying drawings, similar parts and / or features may have the same reference number. Furthermore, various parts of the same type may be distinguished by appending a letter after the reference number that distinguishes between the similar parts and / or features. If only the first reference number is used in the specification, the description is applicable to any of the similar parts and / or features having the same first reference number, regardless of the letter suffix. DETAILED DESCRIPTION OF THE INVENTION

[0020] Detailed Description of the Invention Aspects of the present invention provide a closure device (hereinafter "reel assembly") that has a reduced number of parts compared to conventional closure devices. The reduced number of parts may be provided by integrating one or more of the reel assembly parts into a single part. The integrated part may perform multiple operations, for example, functioning as a lace take-up spool while also functioning as a ratchet rotation mechanism. Reducing the number of parts in the reel assembly simplifies the overall system, thereby reducing the cost and / or complexity of the system. The reduced number of parts may also reduce the risk of part or system damage and / or malfunction.

[0021] Generally, the described reel assemblies may be used to close a variety of articles, such as clothing (i.e., hats, gloves, etc.), sports apparel (boots, snowboard boots, ski boots, etc.), medical braces (i.e., back braces, knee braces, etc.), and various other articles or apparel. Specific aspects in which the closure devices may be used include shoes, boots, and other footwear. For ease of describing the aspects herein, the present disclosure is directed primarily to shoes, although it will be understood that the closure devices may be used with a variety of other articles.

[0022] Referring to FIG. 1 , a perspective view of an embodiment of a lacing system 100 used to tighten a shoe 102 is shown. The shoe can be any suitable footwear that can be tightened around a wearer's foot. The lacing system 100 can be used to close or fasten various other items, such as belts, hats, gloves, snowboard bindings, medical braces, or bags, as described herein. The lacing system can include a reel assembly 104, laces 106, and one or more lace guides 108. In the illustrated embodiment, the reel assembly 104 can be attached to a tongue 110 of the shoe. Various other configurations are also possible. For example, the reel assembly 104 can be attached to a side of the shoe 102, which can be advantageous for shoes designed such that shoe sides 112a-b are drawn close together when tightened, exposing only a small portion of the tongue 110. The reel assembly 104 can also be mounted on the back of the shoe 102, and when mounted on the back, a portion of the lace 106 can be threaded through the shoe 102 on either side of the wearer's ankle (sometimes using tubing to thread the lace) so that the lace 106 can engage with the reel assembly 104.

[0023] Figure 2 is a perspective view of an embodiment of a lacing system 200, which can be similar to lacing system 100 or any other lacing system described herein. The lacing system can include a reel assembly 204, which can be similar to reel assembly 104 or any other reel described herein. Figure 3 is an exploded perspective view of reel assembly 204. Figure 4 is another exploded perspective view of reel assembly 204.

[0024] 2-4, reel assembly 204 may include a base member 214, a spool member 216, and a knob 218. The base member may include a spool housing 220 and a mounting flange 222. The spool housing 220 may include a plurality of ratchet teeth 224 that may extend radially inward. The base member 214 may include race holes 226a-b that allow the race 206 to enter the spool housing 220.

[0025] The spool member 216 can be disposed within the spool housing 220 such that the spool member 216 is rotatable about an axis 228 relative to the spool housing 220. The race 206 can be secured to the spool member 216 such that rotation of the spool member 216 in a tightening direction (indicated by arrow A) draws the race 206 into the spool housing 220 and winds it around a channel 230 formed in the spool member 216, and rotation of the spool member 216 in a loosening direction (indicated by arrow B) unwinds the race 206 from the channel 230 in the spool member 216 and out of the spool housing 220 through race holes 226a-b. The spool member 216 can also include spool teeth 232 formed thereon. It will be understood that the embodiments disclosed herein can also be modified such that rotation in the direction indicated by arrow B tightens the race. In this particular embodiment, to release the lacing, knob 236 may be pulled axially up to disengage spool 230 to allow the spool to rotate freely in direction B. In other embodiments, rotation of the knob in the direction indicated by arrow B (or A) may loosen the lacing system.

[0026] The knob 218 can be mounted to the spool housing 220 such that the knob 218 can rotate about an axis 228 relative to the spool housing 220. The knob 218 can include knob teeth 234 that can be configured to mesh with the spool teeth 232 to couple the knob 218 to the spool member 216 such that rotation of the knob 218 in a tightening direction also rotates the spool member 216 in a tightening direction. In some embodiments, rotation of the knob 218 in a loosening direction can also rotate the spool member 216 in a loosening direction. The knob 218 can also include one or more pawl teeth 236 that can be biased radially outward to mesh with the ratchet teeth 224. The pawl teeth 236 and ratchet teeth 224 can be configured such that when the knob 218 is rotated in a tightening direction, the ratchet teeth 224 move the pawl teeth 236 radially inward, thereby allowing the knob 218 to rotate in the tightening direction. Pawl teeth 236 and ratchet teeth 224 may also be configured such that when a force is applied to twist knob 218 in a loosening direction, pawl teeth 236 and ratchet teeth 224 engage with one another, thereby preventing rotation of knob 218 in the loosening direction.

[0027] Thus, the reel assembly 204 can provide a one-way tightening system configured to allow a user to turn the knob 218 in a tightening direction (which rotates the spool member 216 in the tightening direction, thereby drawing the lace 206 through the lace holes 226a-b and into the spool housing 220). The more the lace 206 is drawn into the spool housing 220, the more the lacing system 200 can tighten, resulting in the lace guide 208 being drawn toward the reel assembly 204 (indicated by arrow C in FIG. 2). While the lacing system 200 is shown as having one lace guide 208, any other suitable number of lace guides can be used. Other features of the reel lacing system are described in U.S. Patent Application No. 2011 / 0266384, entitled "Reel Based Lacing System," filed April 29, 2011, the entire disclosure of which is incorporated herein by reference.

[0028] As noted above, the embodiments described herein integrate one or more of the reel assembly components into a single component to reduce the part count, i.e., the number of parts, of the reel assembly. For example, one or more of the components described in FIGS. 2-4 may be integrated or consolidated into a single component. Reducing the overall part count by integrating or consolidating components simplifies the system and / or reduces costs. In some embodiments, the reel assembly may be assembled without the use of screws or other strong fasteners, which may increase the durability and / or impact resistance of the reel assembly. For example, the individual components of the reel assembly may be configured to snap into engagement with one another, thereby reducing or eliminating the need for strong fasteners, such as screws, rivets, bolts, etc. These and other features of the reel assembly will become more apparent with reference to the embodiments described below.

[0029] 5A-B show an embodiment illustrating how the upper portion or gripped cover 512 and the lower portion or core 514 of the reel assembly knob may be mated into an assembly. Specifically, the gripped cover 512 may be snapped onto the core 514. The gripped cover 512 may have an inwardly extending flange portion 516 that snaps onto an outwardly extending flange 518 of the core 514. When the two parts are mated, the lower portion of the gripped cover 512 generally flexes outward as the flange 516 snaps over the flange 518. The lower portion of the gripped cover 512 then resiliently snaps back into place, locking the gripped cover 512 around the core 514. Because the gripped cover 512 fits over the core 514, the flange 516 of the cover is exposed to external objects. In some circumstances, flange 516 may hit or collide with an external object at an angle, which may cause gripped cover 512 to separate from core 514. To prevent separation of the parts, core 514 and / or gripped cover 512 are generally made of a sturdy material, such as glass-filled nylon, which can be relatively expensive.

[0030] In some embodiments, impact strength can be improved by reversing the bonding configuration. For example, separation of a gripped cover from a core can be prevented or inhibited by reversing the bonding configuration between the components. For example, knob 504 shows a gripped core 524 with a circumferential channel 526 into which the edge of cover 522 fits. This knob 504 configuration is further illustrated in FIG. 5C . When the cover is pressed against gripped core 524, cover 522 may flex inward, or gripped core 524 may flex outward. The edge of cover 522 may snap into circumferential channel 526 to bond the components together. Because the connection between the components is within gripped core 524, knob 504 is less susceptible to side or oblique impacts that might otherwise separate the cover from the core. This configuration may allow for the use of less expensive materials, such as ABS, nylon, or other materials. In some embodiments, cover 522 may include slots 528 that allow cover 522 to be separated from gripped core 524 with leverage, for example, by using a flat head screw driver. In some embodiments, one or more of the components described herein (i.e., pawls, teeth, spools, etc.) may be housed within the combined cover and core.

[0031] 6A-K, a reel assembly 600 having several integrated components is shown. FIG. 6A shows an exploded perspective view of reel assembly 600. As shown, reel assembly 600 includes a spool housing 602 having an interior or chamber within which most of the other components, such as a spool 620 and a pawl or drive disk 640 (hereinafter "pawl disk 640"), fit. Spool housing 602 includes a plurality of circumferentially arranged, radially inwardly facing ratchet teeth 604 configured to engage with pawl teeth 642 on pawl disk 640 when reel assembly 600 is operated to wind lace around spool 620.

[0032] The pawl teeth 642 on the pawl disk 640 and the ratchet teeth 604 on the spool housing 602 function as a ratchet mechanism that provides a one-way winding motion of the spool 620, allowing lace to be wound around the spool. To provide the one-way ratchet mechanism, the pawl teeth 642 are configured to flex radially inward relative to the pawl disk 640 when the pawl teeth 642 rotate clockwise relative to the ratchet teeth 604. The pawl teeth 642 are biased radially outward to engage and lock with the ratchet teeth 604, preventing counterclockwise rotation of the pawl disk 640 relative to the spool housing 602. As the pawl disk 640 and pawl teeth 642 rotate relative to the ratchet teeth 604, the inward and outward flexing of the cantilevered pawl arms causes the pawl teeth to snap into place within the corresponding housing teeth 604, creating an audible "click." This sound can be customized by adjusting the thickness of the pawl disk 640 material.

[0033] Claw plate 640 also includes a plurality of axially oriented teeth 646 (see FIG. 6B ) configured to engage with axially oriented teeth 626 of spool 620. Teeth 646 and 626 engage such that, when claw plate 640 rotates clockwise (or counterclockwise) relative to spool housing 602, claw plate 640 drives, or otherwise causes, clockwise rotation of spool 620. This rotation of spool 620 causes a lace (not shown) attached to spool 620 to wind around a central portion or channel 625 of spool 620. To drive claw plate 640 and spool 620 clockwise, a knob 660 is attached to claw plate 640 via a shaft 662, as described in more detail below. In some embodiments, claw plate 640 can include a keyed recess 648 into which a correspondingly shaped extension or member (not shown) of knob 660 is disposed. Keyed recess 648 and extension may function similarly to teeth 646 and 626 to transmit rotational motion applied to knob 660 by a user to pawl plate 640 and spool 620. To couple the components together (e.g., spool 620, pawl plate 640, and knob 660), axle 662 may be inserted through centrally located opening 627 in spool 620 and centrally located opening 647 in pawl plate 640 and coupled to knob 660. In some embodiments, axle 662 may be sonically welded to knob 660, although other axle-to-knob coupling methods are contemplated herein, such as interference fit, adhesive bonding, heat welding, riveting, etc.

[0034] Pawl disk 640 offers several advantages over pawl disks of other reel assemblies. For example, the arrangement of the curved, cantilevered portions or members of pawl teeth 642 flexes radially outward against ratchet teeth 604 of spool housing 602 when the lace is pulled tight and / or knob 660 is counter-rotated. In this manner, spool housing 602 supports pawl teeth 642 as the curved, cantilevered portions or members push spool housing 602 outward. Additionally, this configuration allows for the location and orientation of pawl teeth 642 to have a more defined and precise position relative to pawl disk 640, which enhances synchronized engagement between pawl teeth 642 and ratchet teeth 604.

[0035] In some embodiments, the spool housing 602 may include a plurality of circumferentially arranged spool housing fingers 606, i.e., fingers configured to engage with an inward flange portion 668 of the knob 660 (see FIG. 6J ), to allow the teeth 626 and 646 of the spool 620 and pawl plate 640 to disengage, thereby allowing the lace to unwind from the spool 620. Specifically, during a reeling operation of the reel assembly 600 as described above, the flange portion 668 of the knob 660 may be positioned axially below the spool housing fingers 606. A plurality of spool housing fingers 622 extending radially outward from the upper flange end of the spool 620 may slideably rest on a stepped inner tab or ledge 608 of the spool housing 602. The stepped inner tab or ledge 608 of the spool housing 602 prevents axial upward movement of the spool 620, pawl plate 640, and knob 660 relative to the spool housing 602. The spool housing fingers 606 described herein offer several advantages over other reel assembly designs. For example, the spool housing fingers 606 may include relatively long preload ramps that provide improved resistance to accidental opening without increasing the overall height of the reel assembly.

[0036] In alternative embodiments, the spool 620 may be inserted into the spool housing 602 from a position axially below the spool housing 602. The spool 620 may be retained within the spool housing 602 by upper and lower flange portions (not shown). In some embodiments, the shaft 662 may be a relatively short axial section such that space is provided in a central portion of the spool 620 to allow for race attachment to the spool 620 at or near the central portion.

[0037] As briefly discussed above, to unwind lace, the teeth 626 and 646 of the spool 620 and pawl disk 640 may be disengaged, allowing the spool to freely rotate counterclockwise (or, in some embodiments, clockwise). Disengagement of the teeth 626 and 646 of the spool 620 and pawl disk 640 is achieved by positioning the lip 641 of the pawl disk 640 axially above the ledge 663 (see FIG. 6I) of the shaft 662. The lip 641 has an inner diameter that is smaller than the outer diameter of the ledge 663. The shaft 662 can slide axially within the central housing of the spool 620 without moving the spool axially upward. Thus, when the knob 660 is pulled axially upward, the ledge 663 of the shaft 662 engages the lip 641, forcing the pawl disk 640 axially upward. The axial upward movement of pawl disk 640 disengages pawl teeth 642 from ratchet teeth 604 on spool housing 602 and disengages teeth 626 and 646 on spool 620 and pawl disk 640, thereby allowing counterclockwise rotation of knob 660, pawl disk 640, and / or spool 620 relative to spool housing 602. This disengagement configuration also allows spool 620 to rotate relative to knob 660 without causing rotation of the cap, which allows lace (not shown) to be unwound from spool 620.

[0038] When the knob 660 is moved axially upward, the inward flange portion 668 of the knob 660 presses against the spool housing fingers 606, deflecting the tabs radially inward. The axially upward movement of the flange portion 668 over the upper surfaces of the spool housing fingers 606 allows the spool housing fingers 606 to return to their undeflected position resiliently, or with a slight preload for a high-quality feel. In this arrangement, the lower surface of the flange portion 668 can rest against the upper surface of the spool housing fingers 606 to maintain the disengaged configuration or relationship of the knob 660 and pawl plate 640 from the spool 620. Because the flange portion 668 can rest against the spool housing fingers 606 in this manner, the user is not required to hold the knob 660 and pawl plate 640 in the disengaged configuration. Rather, a user may pull knob 660 axially upward so that flange portion 668 rests on the tab, release knob 660, unwind lace from spool 620, and then push knob 660 downward to re-engage pawl teeth 642 with ratchet teeth 604 on spool housing 602 and re-engage teeth 626 and 646 on spool 620 and pawl disk 640, after which lace winding may occur as described above. To facilitate re-engagement of the ratchet and pawl teeth, each of these components may have a chamfer or beveled edge that biases the ratchet and pawl teeth in the engagement direction.

[0039] FIGS. 6B and 6C show bottom perspective and top views, respectively, of the claw disk 640. To facilitate re-engagement of the teeth 646 with the teeth 626 of the spool 620, the teeth 646 (and teeth 626) may have a beveled configuration, as shown. FIGS. 6D and 6E show perspective and side views, respectively, of the spool housing 602. These figures also show the spool housing 602 coupled with a bayonet 650, which may be sewn or otherwise attached (e.g., welded, riveted, adhesively bonded, etc.) into the fabric of a shoe, brace, or other apparel or device. The spool housing 602 may be removably coupled with the bayonet to allow removal and / or replacement of the reel assembly 600. FIGS. 6D and 6E further show an opening 607 through which a lace (not shown) may be coupled to the spool 620. FIGS. 6F-J show cross-sectional perspective views of the coupled components of the reel assembly 600.

[0040] 7A-C, another embodiment of a reel assembly is shown. FIG. 7A shows a reel assembly 700 including a base member 702, a spool 704, a core 706, a spring-loaded pawl disk 708, a gripped cover 712, and a coupling mechanism 711 (e.g., a screw) coupling the spring-loaded pawl disk 708, the core 706, the spool 704, and the base member 702 to one another. The base member 702 may be similar to the spool housing 602 in that it includes teeth 716 that mate with pawl teeth 714 of the spring-loaded pawl disk 708 to enable one-way ratcheting, as described above. The base member may also include a flange 717 that is sewn into the fabric of a shoe, brace, or other apparel or device. In some embodiments, the base member 702 may be releasably coupled to a bayonet. The base member 702 may also include a central axis 719 about which the spool 704 and / or core 706 rotate and / or which is coupled to the coupling mechanism 711, for example, by threading the screw 711 through the axis 719.

[0041] As previously described, a lace (not shown) may be wound around the spool 704, which may include teeth 718 that mate with corresponding teeth on the spring-loaded nail disc 708 or core 706. In some embodiments, the spring-loaded nail disc 708 may include a centrally located spring 715 that mates with a bushing 710. In some embodiments, the central spring may be formed of a compliant or resilient material that flexes when the bushing 710 is forced through the central lumen of the spring-loaded nail disc 708. After the bushing 710 is inserted into the central lumen, the resilient material of the spring-loaded nail disc 708 presses against the bushing 710, connecting the components together. A screw 711 may be inserted into the bushing 710 and connected to the base member 702 through the spool 704. A grip-equipped cover 712 fits over the assembly and mates with the base member 702 to cover the assembly and provide a part that the user can grasp and rotate to wind the lace.

[0042] 7B and 7C, another embodiment of a reel assembly is shown. The reel assembly of FIGS. 7B and 7C is similar to that depicted in FIG. 7A in that the reel assembly includes a base member 742, a spool 744, a cover 750, and a coupling mechanism, such as a screw 748 and a bushing 747. The reel assembly of FIGS. 7B and 7C differs from reel assembly 700 in that the system includes a claw-equipped integrated spool housing 746. The outer cylindrical portion of the claw-equipped integrated spool housing 746 fits over the outer cylindrical wall of the base member 742 and can be rotated relative thereto by a user grasping the outer cylindrical portion. The claw portion of the claw-equipped spool housing 746 fits within the inner cylindrical wall of the base member 742, allowing the pawl teeth to engage with the ratchet teeth of the base member 742 to allow lace to be wound and unwound from the spool 744, as described herein. The cover 750 may be similar to that depicted in FIG. 5A and is coupled to the cylindrical interior of the claw-disk spool housing 746 .

[0043] 8A-L, another embodiment of a reel assembly 800 having integrated components is shown. Similar to some of the other reel assemblies described herein, the reel assembly 800 includes a spool housing 802 that releasably couples with a bayonet 804, which may be coupled to a shoe, brace, or other apparel or device by stitching, adhesive bonding, molding, or the like. In some embodiments, to releasably couple the spool housing 802 and the bayonet 804, the bayonet 804 may include a tab 803 having an inwardly or outwardly facing hooked portion that fits within a recess 811 in a lower flange portion of the spool housing 802. The tab 803 may be pulled or pushed to remove the hooked portion from the recess to allow the spool housing and other components of the reel assembly 800 to be released from the bayonet. Separation of the reel assembly 800 may be performed to replace the reel assembly, to replace the reel assembly's laces, or for maintenance or other purposes.

[0044] Reel assembly 800 also includes a pawl spool 806 that fits within spool housing 802. Unlike the other reel assemblies described herein, reel assembly 800 does not include a separate pawl disk. Rather, pawl teeth 805 are integrated into one piece with pawl spool 806, thereby reducing the part count of reel assembly 800. As noted above, pawl teeth 805 are biased radially outward by curved spring elements to urge pawl teeth 805 into engagement with ratchet teeth 807 on the spool housing to provide the one-way ratcheting action described above.

[0045] Reel assembly 800 also includes gripped cover 808 as described above. Spool housing 802 includes spool housing fingers 801 spaced circumferentially around the body of spool housing 802. In some embodiments, fingers 801 may be annular flanges that partially or completely surround spool housing 802. Fingers 801 are hereinafter referred to as flanges 801. Spool housing flange 801 interacts with a corresponding flange or grooved interior channel of gripped cover 808 (see FIGS. 8D-I ) as described above to allow gripped cover 808 to be pulled axially upward and maintained in an axially raised orientation relative to pawl spool 806, disengaging pawl teeth 805 and ratchet teeth 807 and thereby allowing race 820 (see FIGS. 8C-E ) to unwind from pawl spool 806. To join the parts together, a stem 810 may be attached to the central cylindrical element of the gripped cover 808 (see FIGS. 8D-I) by sonic welding, adhesive bonding, press fit, or the like.

[0046] In some embodiments, pawl spool 806 can include a plurality of teeth 817 disposed on its upper surface that engage and interact with teeth (not shown) disposed on the interior of grip cover 808. In other embodiments, grip cover 808 can include splines 814 (see FIGS. 8F-I) that engage with pawl spool 806. As shown in FIGS. 8F-H, when grip cover 808 is initially pulled axially upward, friction between splines 814 and openings 813 in pawl spool 806 moves the spool axially upward to the disengaged position (FIG. 8G), at which point the integrated pawl teeth retract from the ratchet teeth on the housing. At this point, the user can gradually unwind the lace, if desired, and push grip cover 808 axially downward to the closed position, where the pawl reengages with the ratchet teeth. To fully release pawl spool 806, gripped cover 808 may be pulled further axially upward to a second position (FIG. 8H), at which point the pawl teeth disengage from the ratchet teeth and splines 814 disengage from openings 813, which allows pawl spool 806 to move or rotate freely while gripped cover 808 remains stationary.

[0047] To allow the splines 814 to disengage from the openings 813, the shaft 810 can be coupled axially below the lip portion 821 of the pawl spool 806, as shown in FIG. 8F . This allows the shaft 810 to move axially upward a desired distance before disengaging the splines 814 from the openings 813. The frictional engagement between the splines 814 and the openings 813 pulls the gripped cover 808, thereby disengaging the pawl teeth 805 from the ratchet teeth 807, as described above. Locating the shaft 810 axially below the lip portion 821 can also reduce the amount of “wobble” of the gripped cover 808 of the reel assembly 800, providing an advantage over other reel assemblies. In other embodiments, the shaft 810 can be coupled just below the lip portion 821 of the pawl spool 806, such that any axial upward movement of the gripped cover 808 is transferred to the pawl spool 806.

[0048] 8F-H, in some embodiments, the spool housing flange 801 may include two outwardly extending flanges (not shown) configured to hold the grip cover 808 in a first position in which the splines 814 are disengaged from the openings 813 and a second position in which the splines 814 are disengaged from the openings 813 and the pawl teeth 805 are disengaged from the ratchet teeth 807. In other embodiments, the spool housing 802 may include circumferential grooves (not shown) instead of the spool housing fingers 801. A flange portion of the grip cover 808 may fit into a circumferential groove in the spool housing 802, and when the grip cover 808 is pulled axially upward, the flange portion slides into another circumferential groove, holding the grip cover 808 and any attached components in the axially raised position. In some embodiments, this configuration may allow the grip cover 808 to be removed without the use of tools. Removal of the gripped cover 808 exposes the spool, allowing the lace to be easily removed and retied or attached to the spool, for example for replacement.

[0049] As mentioned above, in some embodiments, the reel assembly 800 may be removed to replace the reel assembly's lace 820. FIGS. 8B-E illustrate one embodiment in which the lace 820 may be replaced. Specifically, the spool housing 802 may include an opening 823 for routing or threading the lace 820. The pawl spool 806 may also include an opening 822 for routing or threading the lace 820. In such embodiments, the openings 822 and 823 of the pawl spool 806 and the spool housing 802, respectively, may be aligned, and the lace 820 may be routed through the two openings from either the exterior or interior areas of the reel assembly. To couple the lace to the spool, a knot may be tied in the lace 820 that cannot pass through the opening 822 in the pawl spool 806. In this manner, replacing the lace 820 is relatively quick, convenient, and easy. In some embodiments, the pawl spool 806 may include a slot instead of the opening 822. A slot may extend axially upward from the lower edge of pawl spool 806 to allow race 820 to be slid into the slot during race replacement.

[0050] 8J-L show in further detail the spool of reel assembly 800, which is integrated with pawl 806 and pawl teeth 805. FIGS. 8B and 81 illustrate a method of assembling the components of reel assembly 800. For example, to assemble the components, pawl spool 806 and shaft 810 may be positioned below spool housing 802. Pawl spool 806 is then inserted into the chamber of spool housing 802 and moved axially upward relative to the spool housing until pawl teeth 805 are adjacent ratchet teeth 807 on spool housing 802. To facilitate insertion of pawl spool 806 into spool housing 802, the spool housing may include an angled or beveled portion 816 configured to deflect pawl teeth 805 inward near the lower edges of ratchet teeth 807. When pawl teeth 805 are forced upwardly adjacent ratchet teeth 807 , the pawl teeth may spring radially outward into engagement with ratchet teeth 807 .

[0051] The gripped cover 808 may then be inserted over the prong spool 806 and spool housing 802, with the axle or slug 824 inserted into the central opening of the spool. The spline 814 is inserted into the opening 813 of the prong spool 806. The axle 810 may then be inserted into the central opening of the prong spool 806 until the axle 810 contacts the slug 824. The axle 810 and slug 824 may then be coupled together by sonic welding, adhesive bonding, riveting, heat welding, or the like. Lace may then be threaded through the prong spool and spool housing, and the coupled components may be releasably attached to a bayonet 804 that is coupled to a shoe, brace, or other device or apparel.

[0052] In some embodiments, the inner diameter 817 of the spool housing 802 may be uniform, such that the spool housing need not include the angled portion 816. Rather, the pawl teeth 805 may be deflected inward before inserting the pawl spool 806 into the spool housing 802. The pawl spool may then be moved axially upward until the pawl teeth 805 deflect radially outward and engage the ratchet teeth 807. The remainder of the assembly process may be the same as described above.

[0053] 9A-O, various other embodiments of reel systems and reel assembly components are shown. FIG. 9A shows a reel assembly 900 in which several of the components are integrated into a knob 902. Specifically, the knob 902 includes knob assembly fingers 903 that function similarly to the spool housing fingers (i.e., 606) described in the previous embodiment. The knob assembly fingers 903 are configured to fit over the body of the spool housing 906 and ride over ridges 908 to hold or maintain the knob 902 in either a raised position, in which lace (not shown) can be unwound from the spool 910, or an engaged position, in which the pawl teeth 904 on the knob 902 engage with the ratchet teeth 907 on the spool housing 906. The knob assembly fingers 903 can snap into place when pushed or pulled over the ridges 908. The fingers 903 on the knob eliminate openings in the spool housing 906, making it more difficult for debris to get in. Knob 902 also includes spool teeth 905 that engage with clutch teeth 909 on spool 910 to facilitate winding of the spool. Spool teeth 905 disengage from teeth 909 when knob 902 is in an axially raised position. A pawl plate is incorporated into knob 902. In some embodiments, the pawl plate or mechanism may be snap-fit ​​into the interior of knob 902. In other embodiments, the pawl plate or mechanism may be sonic welded, glued, or otherwise coupled to knob 902, or a pawl mechanism feature may be molded into the knob. Knob 902, or any of the other caps described herein, may include grip features on its exterior surface that allow for improved tactile feel and / or gripping capabilities.

[0054] 9A, when tension is applied to the lace, the rotational force of spool 910 is transmitted to knob 902 through the interaction of teeth 909 and spool teeth 905. This force is in turn transmitted to spool housing 906 through the interaction of pawl teeth 904 and ratchet teeth 907. Because pawl teeth 904 flex inward when the knob is turned to wind the lace, the pawl teeth produce a clicking sound when knob 902 is turned to wind the lace around spool 910.

[0055] As noted above, the spool housing 906 includes an opening (not numbered) that allows the race to exit the spool housing. The geometry of the opening can be configured to enhance race longevity. Similarly, the spool 910 includes a race attachment method, such as the opening or slot described above. In one embodiment, the components of the reel assembly 900 can be assembled by snap-fitting or otherwise attaching the knob 902 and pawl mechanism or knob core. The race can then be inserted inwardly through the race exit (i.e., opening) in the spool housing 906 and attached to the spool 910. The race can then be pulled tight to seat the spool 910 within the body of the spool housing 906. The spool housing 906 can then be attached to the bayonet 912. The knob 902 can then be snapped onto the spool housing 906 by applying pressure until the knob assembly fingers 903 overcome the ridges 908 that surround the outer diameter of the spool housing 906.

[0056] Figure 9B shows a bottom view of knob 902 and further illustrates the various integrated parts of knob 902. Figure 9C shows fingers 903 of knob 902 positioned on a flange of the spool housing. Figure 9C further illustrates the engagement of pawl teeth 904 with ratchet teeth and spool teeth 905 with clutch teeth.

[0057] 9D-F show another embodiment of a reel assembly 920. The reel assembly 920 includes a spool housing 922 having spool housing fingers 923 as described above. The spool housing 922 also includes ratchet teeth 924 that engage with the pawl teeth. The ratchet teeth 924 of the spool housing 922 are located near the underside of the spool housing 922. As in some of the previous embodiments, the pawl teeth 927 may be integral with the spool 928, or may be located on a lower flange of the spool 928. The spool may be inserted into the spool housing 922, and a knob 926 may be located on those components. The knob 926 may include a circumferential groove 929 that engages with a flange portion of the spool housing fingers 923 to allow the knob 926 to rotate relative to the spool housing 922. A slug 925 located in the center of the knob 926 may be inserted into an opening in the spool housing 922 to couple the components together. The knob 926 may engage the spool 926 via interaction between teeth (not shown), a clutch (not shown), or the like.

[0058] 9N and 9O show alternative embodiments of reel assemblies. Specifically, FIG. 9O shows a first reel assembly including a spool housing 952, a knob 954, a spool 955, and a bayonet 956. Pawl teeth and ratchet teeth on the spool 955 and spool housing 952 can engage and interact to provide the unidirectional ratcheting action described herein. As noted above, the pawl teeth can be integral with either the spool 955 or the spool housing 952, while the ratchet teeth can be integral with the other component. The spool housing 952 can also include spool housing fingers or springs that engage with circumferential grooves or flanges on the knob 954 to hold the knob and spool in a position that allows the pawl teeth to disengage from the ratchet teeth and unwind the lace from the spool 955. In some embodiments, the knob 924 can be permanently coupled to the spool 955 by adhesive bonding, welding, or the like. In other embodiments, knob 954 may be removably coupled to spool 955 via a snap fit, press fit, etc. Figure 9N shows a reel assembly similar to that of Figure 9O, except that the knob and spool are integrated into one piece 964 (inserted into spool housing 962). The reel assemblies of Figures 9N and 9O may be removably coupled to bayonets 956 and 966, respectively, to allow for coupling of races 958 and 968, respectively, with the spool.

[0059] 9G-I show another embodiment of a reel assembly. Unlike the other embodiments, the spool 974 of the reel assembly is indirectly coupled to the spool housing 972. For example, the spool 974 includes a slug 975 disposed near its top surface. The slug 975 is inserted into an opening in the spool housing 972 and coupled with a sagittal portion 979 or plug of a cover 976, which in turn is coupled to the spool housing 972 by, for example, inserting an edge of the cover 976 into an internal groove of the spool housing 972. As shown in FIG. 9I, the slug 975 includes deploying barbs that deploy and fit over the sagittal portion 979 when the parts are pressed together. When the barbs deploy, the slug 975 becomes too large to fit through the opening in the spool housing 972, thereby locking the spool 974 in place relative to the spool housing 972. The top surface of spool 974 includes a drive piece 971 that is insertable into a corresponding recess (not numbered) in spool housing 972. Drive piece 971 transmits torque from spool housing 972 to spool 974.

[0060] The spool housing 972 is then coupled to the bayonet 978, for example, by pushing an inwardly facing flange 973 of the spool housing 972 over an outwardly facing flange 977 of the bayonet 978. Alternatively, the inwardly facing flange 973 may press against a circumferential groove (not shown) in the bayonet 978, or vice versa. In operation, the spool housing 972 may be rotated and rotational motion may be transmitted to the spool 974 via a drive part 971, which may include teeth (not shown), friction between the slug 975 and the sagittal portion 979, a clutch mechanism, or the like. The spool housing and bayonet may also include a pawl tooth 970 and ratchet tooth (not numbered) arrangement that enables said one-way ratcheting motion.

[0061] 9J and 9K, an embodiment 980 illustrating a method for coupling components of a reel assembly together is shown. As described herein, a reel assembly may include a spool housing 982, a spool 984, one or more other components 986 (e.g., a pawl, a dial, an integrated knob and pawl mechanism, etc.), and a knob 988. The spool housing 982 may include a centrally located axle 983 that may be inserted into one or more openings in the components (e.g., the spool 984 and the component 986). The axle 983 may have a radially extending opening into which a pin 987 (e.g., a cotter pin) may be inserted to lock the components in place. The knob 988 may then cover the pin 987 and axle 983 when coupled with the spool housing 982.

[0062] 9L and 9M, another embodiment 990 for coupling components of a reel assembly together is shown. Embodiment 990 is similar to embodiment 980 in that the reel assembly may include a spool housing 992, a spool 984, another component (e.g., a pawl, dial, integrated knob and pawl mechanism, etc., not shown), and a knob 986 or cap. Unlike embodiment 980, knob 986 includes a stem 987 that is inserted into an opening in another component. A pin 983 may be inserted into stem 987 on the bottom side or surface of spool housing 992 to couple the components together. The coupled components may then be coupled with a bayonet 988 as described herein.

[0063] 10A and 10B, an embodiment of a spool housing 1002 that can be coupled with a plurality of bayonets 1006 is shown. As described herein, a spool 1004 is inserted into the spool housing 1002 through an open bottom end and manipulated via a reel assembly (not shown). The spool 1004 and spool housing 1002 include slots 1005 and 1003, respectively, that allow for quick and easy replacement of laces (not shown) of a lacing system, as described herein. For example, laces may be easily slid into slots 1003 and 1005 of the spool housing 1002 and spool 1004, and then coupled to the spool 1004.

[0064] The spool housing 1002 also includes a tab or coupling piece 1010 that allows the spool housing 1002 to be removably coupled to the bayonet 1006. To removably couple the pieces, the tab 1010 may be pressed downward against a coupling protrusion 1008 on the bayonet 1006. Another tab (not shown), located on the opposite side of the spool housing 1002, may be inserted into a recess 1009 in the bayonet 1006 to lock the spool housing 1002 in place relative to the bayonet 1006. The bayonet 1006 also includes a channel or access 1007 through which a lace may be inserted to provide access to the spool housing 1002 and spool 1004.

[0065] As shown in FIG. 10B , the bayonet 1006 may be available in multiple styles or configurations. For example, the bayonet 1006 may be available in a variety of channel or port 1007 configurations. In one embodiment, the port 1007b may be spaced approximately 180 degrees apart so that the two lace ends exit the reel assembly approximately diametrically opposed to one another. In another embodiment, the port 1007a may be angularly offset by any desired number of degrees so that the two lace ends are similarly offset. In other embodiments, the port may have an angled configuration (e.g., a 90° bend) so that the lace enters the port and then bends before accessing the spool housing 1002 and spool 1004.

[0066] In some embodiments, the spool housing 1002 and / or spool 1004 includes multiple slots 1003 and 1005 to allow the spool housing 1002 and / or spool 1004 to be removably coupled with multiple bayonets 1006 having different port 1007 configurations. The port 1007 and / or slot 1003 and 1005 configurations may allow one spool housing 1002 to be coupled with a variety of bayonets 1006 to provide a desired lace path or pattern.

[0067] 10C-H, embodiments for coupling a race to a spool housing to facilitate easy race installation and / or replacement are shown. FIG. 10D shows one embodiment of a spool housing 1012 including a recess 1014 into which a base 1016 of a race component fits. The base 1016, when inserted into the recess 1014, can couple the race component to the spool housing 1012. In some embodiments, the base 1016 is removable from the recess 1014 to allow for race replacement. In other embodiments, the base 1016 may be permanently coupled within the recess 1014.

[0068] The lace 1015 extends from a base 1016 and includes a plug or slug 1017 coupled to an end of the lace 1015. In some embodiments, the length of the lace 1015 can be predetermined so that an appropriate lacing component can be selected based on the intended application. In other embodiments, the length of the lace can be changed or adjusted, for example, by submerging the nylon lace in hot water and pulling on the slug 1017 to stretch the nylon lace. After selecting the appropriate length of the lace 1015 or adjusting the lace length as desired, the base 1016 can be coupled to the recess and the lace 1015 can be wrapped around one or more guide pieces 1018. The slug 1017 or end of the lace 1015 can then be inserted into one or more passages or ports 1013 of the spool housing 1012 and coupled to the spool 1019, for example, by inserting the slug into a slot in the spool 1019 as described herein. The slug 1017 may be sized larger than the slot in the spool 1019 to prevent the race from separating from the spool 1019. The spool housing 1012 allows for the race 1015 to be easily removed and replaced if necessary.

[0069] 10F-H show a similar embodiment of a spool housing 1022, except that the lacing piece is integrally formed with the spool housing 1022. Specifically, a base 1024 of the lacing piece is integrally formed with the spool housing 1022 or is otherwise rigidly attached to the spool housing 1022, for example, by radio frequency welding, adhesive bonding, insert molding, or the like. A tension member or race 1025 extends from the base 1024 and includes a slug 1026 attached to the end as described above. The length of the race may be a predetermined amount, or may be varied or adjusted, for example, by submerging nylon race in near-boiling water (which may raise the temperature of the spool housing above a threshold temperature at which the race 1025 can form). In other words, the race 1025 is formed by stretching and deforming the material of the spool housing 1022. The slugs 1026 can facilitate the formation of the lace 1025 by providing a feature that can grip and pull when stretching and deforming the spool housing material. The lace 1025 can be wrapped around one or more guides 1028 and inserted into one or more ports 1023 in the spool housing 1022 before being mated with a spool (not shown). The spool housing components of Figures 10C-H provide one "active" lace, i.e., one lace end that is pulled by the reel assembly or clamping component.

[0070] According to one embodiment, a method of forming a tension member for a lacing system includes securing a base portion (e.g., a spool housing) of material and stretching the base portion to form a tension member having a proximal end integrally attached to the base portion and a distal end opposite the proximal end. The method also includes coupling the distal end of the tension member to a spool. As described herein, the spool is configured to gather the tension member to fasten an article. The method further includes operatively coupling the spool to a clamping component such that operation of the clamping component causes the spool to gather the tension member, thereby fastening the article. In some embodiments, securing the base portion of material is accomplished by gripping a grip feature on the base portion, such as the slug described above. The grip feature / slug facilitates stretching the base portion of material. In some embodiments, stretching the base portion of material can be accomplished when the material is above a threshold temperature, for example, by placing the base portion in boiling water.

[0071] 11A-P, another embodiment of a reel assembly 1100 having various integrated components is shown. The reel assembly 1100 includes a knob 1102, an annular spring 1104, a pawl disk 1106, a spool housing 1108, a spool 1110, a slug 1112, and a bayonet 1114. FIG. 11P shows a top view of the annular spring 1104, detailing that the annular spring 1104 includes interrupted ends 1105 that allow the annular spring 1104 to flex circumferentially and thereby expand and contract radially to raise and lower the knob 1102 relative to the spool housing 1108, as described below. The knob 1102 is configured to be turned by a user, which in turn rotates the pawl disk 1106 within the spool housing 1108 via a drive member, splines, engaging teeth, or the like. The pawl disk 1106 includes pawl teeth that interact with ratchet teeth on the spool housing 1108, as shown in FIGS. 11L-O. The pawl disk 1106 rotates the spool 1112 (e.g., via mating teeth, splines, etc.) to wind and unwind lace as described herein. A slug 1112 couples with the knob 1102 to couple the various components of the reel assembly 1100 together. The spool housing 1108 may be removably coupled with a bayonet 1114.

[0072] 11B-H illustrate the process of assembling the components of the reel assembly 1100. Specifically, in FIG. 11B, an annular spring 1104 is inserted into a groove or recess (not shown) in the knob 1102. The annular spring 1104 is allowed to flex circumferentially and / or radially within the groove in the knob 1102, allowing the diameter of the annular spring 1104 to increase or decrease slightly. In FIG. 11C, a pawl disk 1106 is inserted into the center portion of the knob 1102. The knob 1102 includes a drive component that mates with a corresponding drive component of the pawl disk 1106 to transmit rotational force from the knob 1102 to the pawl disk 1106. In FIGS. 11D and 11E, a spool 1110 is inserted into a spool housing 1108. In FIG. 11F, the knob 1102 and its associated components (i.e., the annular spring 1104 and the pawl disk 1106) are coupled to the spool housing 1108. These components may be joined by coaxially aligning the knob 1102 with the spool housing 1108 and forcing the knob 1102 axially downward against the spool housing 1108, circumferentially deflecting the annular spring 1104 and seating it within the annular groove 1109 of the spool housing 1108. Then, as shown in FIG. 11G, the slug 1112 is inserted into the central opening of the spool 1110 so that the top of the slug 1112 mates with the knob 1102. The knob 1102 and slug 1112 are then joined together to lock or otherwise join the components of the reel assembly 1100 together. Joining the slug 1112 and the knob 1102 may be accomplished by high-frequency welding, adhesive bonding, mechanical fastening, or the like. In a particular welding embodiment, the join between the slug 1112 and the knob 1102 may have a weld diameter of approximately 4.5 mm and a weld height of approximately 1.2 mm. 11H, the spool housing 1108 may then be coupled to the bayonet 1114, for example, by snap-fitting or otherwise coupling the corresponding parts of the spool housing 1108 and the bayonet 1114 together.

[0073] 11I-K illustrate a specific use of the reel assembly 1100. Specifically, an annular spring 1104 may be used to maintain or hold the knob 1102 in a raised or depressed configuration relative to the spool housing 1108. FIG. 11I illustrates a cross-sectional view of the knob 1102 showing the annular spring 1104 disposed within a groove in the knob 1102. FIG. 11J illustrates the knob 1102 in a depressed configuration relative to the spool housing 1108. In this configuration, the annular spring 1104 is disposed within an annular groove 1109 in the spool housing 1108. FIG. 11K illustrates the knob 1102 in a raised configuration relative to the spool housing 1108. In this configuration, the annular spring 1104 is disposed axially above the annular groove 1109 in the spool housing 1108 and may be disposed within a second annular groove in the spool housing 1109. The annular spring 1104 may flex circumferentially and expand slightly in diameter when the knob 1102 is pulled axially relative to the spool housing 1108. The annular spring 1104 may also contract when seated in a second annular groove (not numbered) in the spool housing 1108, which may hold or releasably lock the knob 1102 in the pulled-up configuration relative to the spool housing 1108. In the pulled-up configuration, teeth (not numbered) on the pawl 1106 may disengage from corresponding teeth (not numbered) on the spool 1110 to allow the spool 1110 and any associated laces to unwind relative to the spool housing 1108.

[0074] 11N and 11O illustrate the interaction between the pawl disk 1106 and the spool housing 1108. Specifically, the pawl disk 1106 includes a plurality of arms with pawl teeth disposed at their distal ends. The distal ends of the arms also include tabs 1107 configured to move radially on the surface of the pawl disk 1106 when the arms flex radially inward due to ratchet-like movement of the pawl teeth against the ratchet teeth on the spool housing 1108. Because the tabs 1107 are disposed on the upper surface of the pawl disk 1106, the tabs 1107 pull the pawl teeth axially upward when the knob 1102 is pulled axially upward relative to the spool housing 1108. The axial upward movement of the pawl teeth via the tabs 1107 disengages the pawl teeth from the ratchet teeth on the spool housing 1108. When the pawl disk 1106 is inserted into the spool housing 1108 , the pawl teeth on the pawl disk 1106 interact with the ratchet teeth on the spool housing 1108 .

[0075] 12A-N, another embodiment of a reel assembly 1200 having various integrated components is shown. Specifically, the reel assembly 1200 includes a clamping component or knob 1202 (hereinafter "knob 1202"), a pawl or drive component 1204 (hereinafter "pawl 1204"), a spool housing 1206, a spool 1208, an attachment or coupling component 1210 (hereinafter "coupling component 1210"), and a bayonet 1212. The attachment component 1210 in this embodiment can also be used as a mechanism to facilitate opening and closing the knob 1202. In this manner, the number of components in the reel assembly 1200 is reduced, making assembly of the reel assembly 1200 relatively quick and easy. The knob 1202, pawl 1204, spool housing 1206, and bayonet 1212 function similarly to the other reel assembly components described herein.

[0076] For example, the pawl plate 1204 may include pawl teeth (not numbered) configured to engage corresponding housing teeth to allow the spool 1208 to rotate in a first direction (e.g., clockwise) while preventing rotation of the spool 1208 in a second direction (e.g., counterclockwise). The pawl plate 1204 may also include spool teeth (not numbered) that releasably engage with corresponding teeth (not numbered) on the spool 1208 to transmit rotational force, i.e., torque, applied by a user to the knob 1202. The pawl plate 1204 may further include a central opening or feature that snaps around a central post of the coupling piece 1210 to allow the pawl plate 1204 to move between engaged and disengaged states.

[0077] 12B-J, a method of assembling the reel assembly 1200 is shown. To assemble the parts, the pawl plate 1204 is coaxially aligned with the knob 1202 and pressed axially downward against the knob 1202 into the recessed areas of the knob 1202. The pawl plate 1204 includes a central opening or recesses that fit over the knob's projections 1203. The projections 1203 snap into grooves or notches in the pawl plate 1204 to lock the pawl plate 1204 in place relative to the knob 1202 and / or to transfer rotational force, i.e., torque, input by the user to the knob 1202. The locking of the projections 1203 to the pawl plate 1204 is shown in more detail in the cross-sectional view of FIG. 12C. When the pawl disk 1204 is inserted into the knob 1202, a shoulder (not numbered) on the knob 1202 pushes the pawl teeth (not numbered) radially inward to an "in use" compressed position, which allows the pawl teeth to smoothly engage with the ratchet teeth (not numbered) on the spool housing 1206.

[0078] As shown in FIG. 12D , the assembled claw disk 1204 and knob 1202 are coaxially aligned with the spool housing 1206, and the knob 1202 is pushed axially downward toward the spool housing 1206. The spool housing 1206 includes an open upper end and an open lower end. To couple the knob 1202 to the spool housing 1206, the claw disk 1204 is inserted into the upper end of the spool housing so that it faces the interior region of the spool housing 1206. The claw disk 1204 rests on and / or is axially above a partition 1207 in the spool housing 1206, which divides the interior region of the spool housing into an upper portion and a lower portion. In some embodiments, the partition 1207 is an annular ring formed or disposed within the spool housing 1206.

[0079] 12E , the knob 1202 includes one or more flange portions 1222 that project radially inward from a grip portion or outer edge of the knob 1202. When the knob 1202 is pressed axially downward against the spool housing 1206, the flange portions 1222 flex and overcome an annular ridge 1223 on the spool housing 1206. The flange portions 1222 of the knob 1202 and the annular ridge 1223 on the spool housing 1206 prevent the knob 1202 from separating from the spool housing 1206. In some embodiments, the flange portions 1222 may be an annular ring that completely or substantially surrounds the spool housing 1206.

[0080] Next, as shown in FIG. 12F, the spool 1208 can be inserted into the central region of the assembled spool housing 1206 and other components (i.e., the knob 1202 and the claw disk 1204). The spool 1208 is inserted into the open bottom end of the spool housing 1206. The spool 1208 can be inserted so that it rests on or is adjacent to the partition 1207 in the lower portion of the spool housing 1206. After being inserted into the open bottom end of the spool housing 1206, the spool 1208 faces the lower end of the claw disk 1204. As shown in FIG. 12F, when the reel assembly 1200 is assembled, the spool 1208 is substantially positioned within the interior region of the spool housing and is accessible from the open bottom end of the spool housing. This allows a user to couple a lace or another tension member to the spool 1208 while the spool is positioned within the interior region of the spool housing. As used herein, "the spool 1208 is disposed substantially within the interior region of the spool housing" refers to more than 80% of the spool 1208 (defined as the volume of the spool defined by the outer wall of the spool housing and the planes located over the open top and bottom ends of the spool housing) being within the interior region of the spool housing. In some embodiments, more than 90% of the spool 1208 is within the interior region of the spool housing, and in some embodiments, the spool 1208 is disposed all or completely within the interior region of the spool housing.

[0081] 12G, the coupling piece 1210 is then coupled to the spool housing 1206 such that a central boss or coupling member extends through a central opening in the spool 1208 and spool housing 1206 and couples with the pawl plate 1204. The coupling between the central boss and the pawl plate 1204 operatively couples the pawl plate 1204 and the spool 1208 such that manipulation of the knob 1202 rotates the spool 1208 in a first direction (e.g., clockwise) within the housing while preventing rotation of the spool piece in a second direction (e.g., counterclockwise). Operatively coupling the pawl plate 1204 and the spool 1208 can be achieved by engaging corresponding teeth on the pawl plate 1204 and the spool 1208, or by engaging splines or other torque (rotational force) transmitting mechanisms or components.

[0082] In some embodiments, coupling piece 1210 includes a relatively flat bottom member that straddles spool 1208 and / or spool housing 1206, preventing coupling piece 1210 from moving axially upward relative to the other components of reel assembly 1200. FIG. 12H shows that in some embodiments, coupling piece 1210 can include attachment members 1224 that snap into corresponding slots in spool housing 1206 to further hold coupling piece 1210 in place relative to the other components of reel assembly 1200. After coupling piece 1210 is snapped into place, knob 1202, pawl 1204, spool housing 1206, and spool 1208 are securely coupled to one another. The spool housing 1206 and other assembled components can then be removably coupled with bayonet 1212, as shown in FIG. 12I.

[0083] In some embodiments, the process of assembling the reel assembly 1200 is performed in a manner such that the reel assembly 1200 does not include screws or other rigid fasteners. For example, the pawl disk 1204 may mate with the knob 1202 by snapping the drive piece into a recessed portion of the fastening piece. Similarly, the knob 1202 may mate with the spool housing 1206 by snapping a lip or flange of the knob over a corresponding lip or flange of the spool housing 1206. The coupling piece 1210 may likewise be snapped into engagement with the bottom end of the spool housing 1206. A central boss of the coupling piece 1210 may snap into engagement with an opening in the pawl disk 1204, and the assembled reel assembly 1200 may snap into engagement with a bayonet 1212 disposed on a shoe or other item to be fastened. In such embodiments, assembly of the reel assembly 1200 involves all or substantially snapping the various parts into engagement, and does not involve the use of screws, rivets, or other rigid fasteners.

[0084] Additionally, the number of parts or components in the reel assembly 1200 is minimal, which reduces the overall manufacturing cost of manufacturing and / or assembling the reel assembly 1200. For example, the number of parts in the reel assembly 1200 may be approximately six or less, including the knob 1202, the pawl 1204, the spool housing 1206, the spool 1208, and the coupling component 1210. In some embodiments, the bayonet 1212 may be included in the number of parts. In some embodiments, the reel assembly 1200 may have five or fewer parts, and / or some of the parts may be combined or integrated. For example, the pawl 1204 may be integrated or integrated with the spool 1208. In another embodiment, the coupling component 1210, specifically the central boss that allows the assembly to remain in an engaged or disengaged position, may be integrated or integrated with the spool 1208.

[0085] In some embodiments, one or more of the components may include two or more parts that are coupled together. For example, the knob may include a body and a gripping body disposed on the periphery of the body. The gripping body may have a coefficient of friction greater than that of the body to enable gripping of the knob 1202. In another embodiment, the bayonet 1212 may include an attachment mechanism configured to releasably couple with the spool housing 1206 and may include an attachment mechanism (e.g., a sewn flange) configured to couple with a shoe or other item. The attachment mechanism may be made of a first material, and the attachment mechanism may be made of a second material that is softer than the first material. The softer second material may allow for easy coupling or attachment of the bayonet 1212 to a shoe or other item, while the harder first material provides a rigid mechanism that enables or facilitates coupling of the bayonet with the spool housing 1206. Separate parts or members may be integrally formed together by two-cavity molding, radio frequency welding, sonic welding, etc., so that the resulting part essentially resembles or functions as a single-piece part.

[0086] 12J shows one embodiment in which the spool housing 1206 can be removably coupled to the bayonet 1212. In this embodiment, one or more interlocking tabs 1226 of the spool housing 1206 can be disposed under undercuts or grooves 1225 in the bayonet 1212. One of the undercuts 1225 can be formed from, or otherwise defined by, a depressible tab or button 1228. The tab 1226 can be released or removed from the undercut 1225 when the button 1228 is pressed. In this manner, the spool housing 1226 and other components of the reel assembly 1200 can be separated from the bayonet 1212 as desired.

[0087] 12K and 12L, there is shown an embodiment of a coupling element 1210 used to facilitate opening and closing the knob 1202 to allow for unwinding or counter-rotation of the spool 1208 and any lace associated therewith. In other words, the coupling element is used to move the pawl disk between an engaged state and a disengaged state, which allows for the release of lace tension. FIGS. 12K and 12L also show the coupling element 1210 associated with the pawl disk 1204 to lock or otherwise couple the components of the reel assembly 1200 together, as previously described.

[0088] 12K shows the knob 1202 disposed in a depressed configuration relative to the spool housing 1206. In this configuration, a flange or bushing 1232 of the pawl disk 1204 is disposed within a first annular groove of the coupling piece 1210 or beneath a radial protrusion or feature on a central boss of the coupling piece. The placement of the bushing 1232 within the first annular groove or beneath the radial protrusion of the coupling piece 1210 holds or otherwise maintains the knob 1202 in a depressed configuration relative to the spool housing 1206. In the depressed configuration, the pawl teeth of the pawl disk 1204 engage with ratchet teeth on the spool housing 1206 as described herein, allowing the spool 1208 to be wound in a ratchet-like manner.

[0089] 12L shows the knob 1202 disposed in a raised configuration, in which the knob 1202 and pawl disk 1204 are moved axially upward relative to the spool housing 1206, spool 1208, and coupling piece 1210. In the raised configuration, the bushing 1232 of the pawl disk 1204 is moved axially upward, out of the first annular groove of the coupling piece 1210, and into the second annular groove of the coupling piece 1210. In other embodiments, the bushing 1232 is raised axially so as to be located above a radial protrusion or feature of a central boss of the coupling piece. The placement of the bushing 1232 in the second annular groove or above the radial protrusion of the coupling piece 1210 holds or otherwise maintains the knob 1202 and pawl disk 1204 in the raised configuration relative to the spool housing 1206. In the raised configuration, the pawl teeth of the pawl disk 1204 are disengaged from the ratchet teeth of the spool housing 1206 as described herein.

[0090] 12L also shows that the interaction between the flange 1222 and the annular ridge 1223 prevents further axial upward movement of the knob 1202 and pawl disk 1204 relative to the spool housing 1206, thereby preventing the knob 1202 from separating from the spool housing 1206. To allow the bushing 1232 of the pawl disk 1204 to be moved axially upward or downward of the radial protrusions or features of the coupling piece 1210, the central boss of the coupling piece includes two members that extend axially upward into the interior region of the spool housing. The two members have a fork-shaped configuration that separates to allow the two members to flex radially inward as the bushing 1232 moves axially upward and downward. In this manner, the central boss of the coupling piece functions as a spring to allow the knob 1202 and pawl disk 1204 to be moved axially and maintained in an axially raised or depressed position.

[0091] The fork-shaped central boss can be configured to ensure there is no or limited “slop” or rattle between the knob 1202 and the spool housing 1206. This is achieved by the geometry of the fork-shaped profile of the central boss and its interaction with the pawl bushing 1232 (which has a preload / interference between them). A “transition point” on the profile of the central boss is important to reduce unintended opening and axial movement of the knob 1202. The “transition point” refers to the widest portion of the radial projection of the central boss. The central boss is configured such that the transition point is located axially above the bushing 1232 when the assembly is engaged or closed, i.e., when the assembly is in the depressed position. As such, if the knob 1202 experiences a sidewall load that tilts the knob 1202 slightly upward, the bushing 1232 will remain below the transition point of the central boss, thereby maintaining the assembly in the engaged or closed state. The radial protrusions of the central boss are also axially canted above and below the transition point to help ensure that the knob 1202 and other components remain in the open / disengaged or closed / engaged position as desired. If the bushing 1232 is positioned axially above the transition point, the configuration and placement of the bushing 1232 and the transition point ensure that the knob 1202 and other components remain in the open / disengaged state. In contrast, if the bushing 1232 is positioned axially below the transition point, the knob 1202 and other components remain in the closed / engaged state. In some embodiments, the central boss can be made of a reinforced polymer material (e.g., 25% GF POM) to provide sufficient stiffness and ductility to help maintain the knob 1202 and other components in the open / disengaged or closed / engaged position as desired.

[0092] In some embodiments, knob 1202 and pawl plate 1204 can be raised or depressed axially by pushing or pulling knob 1202. In other embodiments, knob 1202 and pawl plate 1204 can be raised or depressed axially by rotating knob 1202 in a second direction (e.g., counterclockwise) and / or by pressing a button or other mechanism.

[0093] To facilitate disengagement of the pawl teeth from the ratchet teeth, pawl disk 1204 includes tabs 1236 disposed on the ends of pawl tooth arms 1235 as described herein. If pawl disk 1204 is pulled axially upward, for example by knob 1202, tabs 1236 pull the pawl teeth upward, facilitating disengagement of the pawl teeth from the ratchet teeth. Figures 12M and 12N show pawl disk 1204 in further detail and also show pawl disk 1204 interacting with coupling piece 1210 while the pawl teeth are engaged with the ratchet teeth.

[0094] Figure 12O shows a similar embodiment of a reel assembly 1200 having the various components described above. However, the embodiment of Figure 12O differs in that the race inlet and outlet 1237 are located on the spool housing 1206 rather than on the bayonet 1212.

[0095] According to one embodiment, a method of assembling a reel assembly includes coupling a drive component (e.g., a pawl) with a clamping component (e.g., a knob). The method also includes coupling the clamping component to an upper end of a housing (e.g., a spool housing) such that the drive component faces an interior region of the housing. The method further includes inserting a spool component (e.g., a spool) into a lower end of the housing such that the spool component is disposed within the interior region of the housing and such that the upper end of the spool component faces a lower surface of the drive component. The method further includes coupling an attachment component to the lower end of the housing. The attachment component includes a coupling member that couples with the drive component. The coupling member and the drive component can operatively couple the drive component and the spool component such that operation of the clamping component rotates the spool component in a first direction within the housing while simultaneously preventing rotation of the spool component in a second direction.

[0096] In some embodiments, one or more of the various components are assembled or coupled such that the reel assembly does not include screws or other rigid fasteners. In some embodiments, coupling the drive component with the clamping component includes snapping the drive component into a recessed portion of the clamping component. In some embodiments, coupling the clamping component with the upper end of the housing includes snapping a lip of the clamping component over a corresponding lip of the housing. In some embodiments, coupling the attachment component with the lower end of the housing includes snapping a flange of the attachment component into an opening in the housing. In some embodiments, the method may further include snapping a coupling member of the attachment component into an opening in the drive component to couple the components together, and / or the method may include coupling the assembled reel assembly with a mounting component disposed on an article to be clamped by the reel assembly.

[0097] In one embodiment, a reel assembly for fastening a shoe or other article includes a housing having an interior region and a partition dividing the interior region into an upper portion and a lower portion, and a spool rotatably disposed within the lower portion of the interior region of the housing, axially below the partition. The partition can prevent the spool from moving axially upward into the upper portion. The reel assembly also includes a drive component disposed within the upper portion of the interior region of the housing. The drive component can be axially movable relative to the spool between an engaged state and a disengaged state. In the engaged state, the drive component allows the spool to rotate in a first direction within the interior region of the housing while preventing rotation of the spool component in a second direction. In the disengaged state, the drive component allows the spool to rotate in the second direction within the interior region of the housing.

[0098] The reel assembly also includes a clamping component disposed axially above and coupled to the drive component, such that operation of the clamping component rotates the spool in a first direction within the interior region of the housing. The reel assembly further includes an attachment component disposed axially below the spool, the attachment component including a coupling member projecting axially upward into the interior region of the housing and coupled to the drive component.

[0099] Having described several embodiments, it will be understood by those skilled in the art that various modifications, alternative constructions, and equivalents may be used without departing from the spirit of the present invention. Additionally, in order to avoid unnecessarily obscuring the present invention, some well-known processes and elements have not been described. Therefore, the above detailed description should not be construed as limiting the scope of the present invention.

[0100] When a range of numerical values ​​is provided, it is understood that each intervening value, to the tenth of the unit of the lower limit (unless the context clearly dictates otherwise), is also specifically disclosed. Each smaller range between any stated or intervening value in a stated range and any other stated or intervening value in that stated range is encompassed. The upper and lower limits of these smaller ranges may independently be included in or excluded from the range, and each range in which either or both ranges are included in the smaller ranges, or neither range is included in the smaller ranges, is also encompassed within the invention, subject to any specifically excluded limits in that stated range. When a stated range includes one or both of the limits, ranges excluding either or both of those included limits are also included.

[0101] As used in this specification and claims, the singular forms "a," "an," and "the" include plural referents unless the context clearly dictates otherwise. Thus, for example, a reference to "a process" includes a plurality of such processes, a reference to "the apparatus" includes a reference to one or more apparatus and equivalents thereof known to those skilled in the art, and so on.

[0102] Furthermore, the words "comprise," "comprising," "include," "including," and "includes," as used in this specification and the claims, are intended to specify the presence of stated features, integers, parts, or steps, but do not exclude the presence or addition of one or more other features, integers, parts, steps, operations, or groups.

Claims

[Claim 1] a housing part having an interior region; a spool component rotatably disposed within an interior region of said housing component, said spool component having an annular channel formed therein about which tension members are gathered to tighten an article; a drive component disposed axially above and operably coupled to the spool component to permit rotation of the spool component in a first direction within the interior region of the housing component while preventing rotation of the spool component in a second direction; a clamping component rotatably coupled within the housing component and disposed axially above and coupled with the drive component, such that operation of the clamping component causes the spool component to rotate in a first direction within an interior region of the housing component to gather the tension member around the annular channel of the spool component, thereby clamping the article; and an attachment part disposed axially below the spool part, the attachment part having a coupling member projecting axially upward into an interior region of the housing part to couple the attachment part to the drive part; containing six or fewer separate parts, A reel assembly for fastening an article.

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