Modular Lacing Engine Architecture for Footwear Automation
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Solution Overview
Problem
Existing motorized lacing systems for footwear face challenges such as high cost of manufacture, complexity, assembly difficulties, and poor serviceability, which hinder their adoption for mass production and daily use.
Innovation Solution
A modular footwear platform that accommodates both motorized and non-motorized lacing engines, featuring a mid-sole plate that allows for late assembly at the point of purchase, and lacing architectures that smooth out lace tension and enhance comfort while maintaining fit performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If motorized lacing systems are implemented in footwear, then lacing automation and fit performance are improved, but manufacturing cost and device complexity increase
Solution Approach 1:
The lacing system is divided into independent modular components: a lacing engine housed in a lacing engine housing, a separate mid-sole plate, lace guides, and a power source. This segmentation allows each component to be manufactured, tested, and replaced independently, reducing overall system complexity while maintaining automation functionality.
Solution Approach 2:
The lacing engine is designed as a universal component that can be integrated into different footwear configurations and styles. The standardized lacing engine housing and mid-sole plate interface allow the same core mechanism to serve multiple footwear products, reducing manufacturing complexity and cost across product lines.
2Extent of automation
If motorized lacing systems are implemented in footwear, then lacing automation is improved, but manufacturing cost increases
Solution Approach 1:
The lacing engine housing and mid-sole plate are pre-assembled as integrated units during manufacturing, with the lacing engine pre-positioned and secured. This preliminary assembly reduces complexity during final footwear assembly and enables more efficient manufacturing processes, lowering overall production costs.
Solution Approach 2:
The system allows for easy replacement of the power source and lacing engine components by the end user or service technician, reducing the need for complex disassembly tools and procedures. This self-service capability simplifies manufacturing requirements and reduces service costs.
3Extent of automation
If motorized lacing systems are implemented in footwear, then lacing automation is improved, but serviceability deteriorates
Solution Approach 1:
The lacing system is divided into serviceable modules including the lacing engine, power source, and lace guides that can be independently accessed and replaced. The lacing engine housing provides access points for servicing internal components without requiring complete disassembly of the footwear, significantly improving serviceability.
Solution Approach 2:
The power source and lacing engine are designed as extractable components that can be removed from the footwear for replacement or servicing. This extraction capability allows technicians to service or replace malfunctioning components without damaging or disassembling the entire footwear structure.
4Ease of operation
If lace guides are distributed along medial and lateral sides, then lace tension distribution and comfort are improved, but device complexity increases
Solution Approach 1:
Lace guides are strategically positioned at specific locations along the medial and lateral sides of the footwear upper to optimize lace tension distribution. Each lace guide is placed where it most effectively contributes to comfort and fit, rather than uniformly distributing guides throughout the entire structure, thereby achieving comfort benefits with minimal added complexity.
Data Source
AI summary
Systems and apparatus related to footwear including a modular lacing engine are discussed. In this example, the footwear assembly can include a footwear upper and a lace cable running through a plurality of lace guides. The plurality of lace guides can be distributed along the medial side and the lateral side, and each lace guide of the plurality of lace guides can be adapted to receive a length of the lace cable. The lace cable can extend through each of the plurality of lace guides to form a pattern along each of the medial side and lateral side of the footwear upper. The footwear assembly can also include a medial proximal lace guide routing the lace cable into a lacing engine disposed within a mid-sole portion. Finally, the footwear assembly includes a lateral proximal lace guide to route the lace cable out of the lacing engine.