3D Drum Encoder for Compact Autolacing Footwear Motors

Solution Overview

Problem

Conventional optical encoders in articles of footwear, such as athletic shoes, are fragile and have a high stack-up, compromising their effectiveness and robustness, especially during athletic activities.

Innovation Solution

The implementation of a three-dimensional optical encoder in the form of a drum or cylinder, which is more compact and robust, coupled with a motorized lacing system that includes a processor circuit and an optical sensor to control lace tension based on detected encoder tabs, enhancing manufacturing ease and durability.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If conventional optical encoders are used in articles of footwear, then the encoder can detect rotational position, but the encoder is fragile and has high stack-up, compromising robustness

Engineering Contradiction:

Improverotational position detectionVSAvoidencoder robustness

Core Design Contradiction:

Measurement precisionVSReliability

Solution Approach 1:

The patent transitions from a conventional two-dimensional flat encoder design to a three-dimensional drum-shaped encoder. The encoder features a cylindrical drum with circumferential markings that rotate with the motor shaft, allowing the optical sensor to detect rotational position by monitoring light transmission through or reflection from the drum surface. This three-dimensional configuration reduces the encoder's stack-up height while improving its robustness against external forces during athletic activities.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

2Measurement precision

If conventional optical encoders are used in articles of footwear, then the encoder can provide positional feedback, but the high stack-up compromises compactness and effectiveness

Engineering Contradiction:

Improvepositional feedbackVSAvoidencoder stack-up

Core Design Contradiction:

Measurement precisionVSVolume of moving object

Solution Approach 1:

The patent transitions from a conventional two-dimensional flat encoder design to a three-dimensional drum-shaped encoder. The encoder features a cylindrical drum with circumferential markings that rotate with the motor shaft, allowing the optical sensor to detect rotational position by monitoring light transmission through or reflection from the drum surface. This three-dimensional configuration reduces the encoder's stack-up height while improving its robustness against external forces during athletic activities.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

3Measurement precision

If conventional optical encoders are used, then rotational detection is possible, but the encoder is vulnerable to damage from external forces during athletic activities

Engineering Contradiction:

Improverotational detectionVSAvoiddamage from external forces

Core Design Contradiction:

Measurement precisionVSObject-affected harmful factors

Solution Approach 1:

The patent transitions from a conventional two-dimensional flat encoder design to a three-dimensional drum-shaped encoder. The encoder features a cylindrical drum with circumferential markings that rotate with the motor shaft, allowing the optical sensor to detect rotational position by monitoring light transmission through or reflection from the drum surface. This three-dimensional configuration reduces the encoder's stack-up height while improving its robustness against external forces during athletic activities.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The three-dimensional optical encoder provides improved robustness and compactness, reducing the likelihood of damage from external forces and enabling effective lace tension control in athletic footwear.

Implementation Method 1

an optical sensor positioned within optical range of the three-dimensional encoder and configured to output a signal to the processor circuit indicative of a detected one of the plurality of tabs

Methodology Applied

Scientific EffectOptical detection: Photoelectric Effect

Data Source

PatentUS20250213005A1Autolacing footwear motor having rotary drum encoder

Publication Date: 2025.07.03 NIKE INC

AI summary

An article of footwear, method, and motorized lacing system includes a motor, including a motor shaft, a spool, coupled to the motor shaft, configured to spool and unspool the lace based on the turning of the motor shaft, a processor circuit, and a three-dimensional encoder. The three-dimensional encoder defines a major axis and has a surface having a tabs extending from a drum, an optical sensor, positioned within optical range of the cylindrical encoder, configured to output a signal to the processor circuit indicative of a detected one of the tabs, and a beam break, positioned between the three-dimensional encoder and the optical sensor, forming a pair of slits. The optical sensor is positioned to view the tabs through the pair of slits, wherein the processor circuit is configured to operate the motor based, at least in part, on the signal as received from the optical sensor.