Modular Footwear Lacing Engine for Assembly and Serviceability
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Solution Overview
Problem
Existing motorized lacing systems for footwear suffer from high manufacturing costs, complexity, assembly challenges, lack of serviceability, and fragile mechanical mechanisms, making them unsuitable for mass production and daily use.
Innovation Solution
A modular footwear platform with interchangeable motorized and non-motorized lacing engines, featuring a robust design with serviceable components, reliable operation, and streamlined assembly processes, including a mid-sole plate that allows for late-stage integration of lacing engines and tactile/visual feedback through LED lighting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If motorized lacing systems are implemented in footwear, then automated tightening function is achieved, but manufacturing cost increases
Solution Approach 1:
The lacing system is divided into independent modular components: a lacing engine module containing the spool and drive mechanism, a motor module, and a control module. Each module can be manufactured separately and assembled into the footwear, enabling mass production and reducing overall manufacturing complexity and cost.
Solution Approach 2:
The lacing engine is designed as a universal module that can be integrated into different footwear types and styles. The standardized interface and mounting system allow the same automated lacing mechanism to serve multiple product lines, reducing per-unit manufacturing cost through economies of scale.
2Extent of automation
If motorized lacing systems are implemented in footwear, then automated tightening function is achieved, but device complexity increases
Solution Approach 1:
The system is segmented into distinct functional modules (lacing engine, motor, control circuitry) that can be developed, tested, and maintained independently. This modular architecture reduces overall system complexity by isolating functions and simplifying the integration process.
Solution Approach 2:
The lacing engine incorporates a self-contained spool mechanism with integrated lace guidance and tensioning features. The mechanism automatically manages the lace routing and winding process without requiring external mechanical assistance, reducing the number of components needed.
3Extent of automation
If motorized lacing systems are implemented in footwear, then automated tightening function is achieved, but assembly difficulty increases
Solution Approach 1:
The lacing engine is provided as a pre-assembled module that can be integrated into the footwear in a single assembly step. The module includes all necessary mechanical components (spool, housing, mounting features) already configured and connected, significantly simplifying the overall footwear assembly process.
4Extent of automation
If motorized lacing systems are implemented in footwear, then automated tightening function is achieved, but serviceability decreases
Solution Approach 1:
The modular lacing engine can be removed and replaced as a single unit, and individual components within the module (such as the spool or motor) can be accessed and serviced independently. This segmentation enables efficient repair and maintenance without requiring disassembly of the entire footwear.
Solution Approach 2:
The design allows for easy replacement of worn or damaged lacing engine modules, and components such as the spool can be recovered and reused in new modules, facilitating cost-effective servicing and extending product life.
5Extent of automation
If motorized lacing systems are implemented in footwear, then automated tightening function is achieved, but mechanical reliability decreases
Solution Approach 1:
The spool is extracted as a separate, serviceable component from the lacing engine housing, allowing it to be removed, inspected, and replaced independently. This extraction simplifies maintenance procedures and improves reliability by enabling quick replacement of worn spools without discarding the entire lacing mechanism.
Data Source
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AI summary
Systems and apparatus related to automated tightening of a footwear platform including a footwear lacing apparatus are discussed. In an example, a footwear lacing apparatus can include a housing structure, a spool, and a drive mechanism. The housing structure can include a top section and a bottom section. The spool can include a superior surface, a lace spool under the superior surface and a spool shaft with a keyed connection pin. The spool can also be integrated into the top section of the housing structure. The drive mechanism can couple with the spool via the keyed connection pin on the spool shaft. The drive mechanism can be adapted to rotate the spool to tighten or loosen a lace cable integrated into the footwear.