Modular Footwear Lacing Engine for Tension Detection and Serviceability
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Solution Overview
Problem
Existing motorized lacing systems in footwear face challenges such as high cost, complexity, assembly difficulties, and poor serviceability, which hinder their adoption for mass production and daily use.
Innovation Solution
A modular footwear platform with interchangeable motorized and non-motorized lacing engines, incorporating innovative designs like load cell force detection, electrode impedance measurement, lever and divot assemblies, split-spool configurations, and optical sensors to detect lace position and tension, enabling robust and serviceable automated lacing systems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If motorized lacing systems are implemented in footwear, then automated lace tightening function is achieved, but cost and complexity increase
Solution Approach 1:
The lacing system is divided into modular components: a lacing engine assembly that can be independently removed and replaced, lace cables that are separate replaceable elements, and a footwear platform that provides the structural framework. This segmentation allows each component to be optimized independently and simplifies maintenance by enabling replacement of only the lacing engine or lace cables without replacing the entire system.
Solution Approach 2:
The lacing engine assembly is designed as a universal component that can be interchanged between different footwear platforms. The standardized interface and mounting mechanism allow the same lacing engine to function across multiple shoe models, reducing overall system complexity and enabling economies of scale in manufacturing and service.
2Extent of automation
If motorized lacing systems are implemented in footwear, then automated lace tightening function is achieved, but manufacturing cost increases
Solution Approach 1:
By segmenting the system into a reusable footwear platform and replaceable lacing engine assembly, manufacturing costs are reduced through platform standardization. The platform can be produced in large volumes with fixed tooling, while the lacing engine assembly becomes a separate manufacturable module that can be optimized independently for cost-effective production.
Solution Approach 2:
The design enables recovery and reuse of the expensive lacing engine assembly and footwear platform, while only the consumable lace cables are discarded and replaced. This extends the service life of the high-cost components and reduces the frequency of expensive replacements, lowering the overall cost of ownership.
3Extent of automation
If motorized lacing systems are implemented in footwear, then automated lace tightening function is achieved, but assembly difficulty increases
Solution Approach 1:
The lacing engine assembly is designed as a pre-assembled modular unit that interfaces with the footwear platform through standardized mounting points. This segmentation allows the lacing engine to be assembled and tested independently before installation into the final footwear product, significantly simplifying the overall assembly process and reducing the skill level required for final assembly.
Solution Approach 2:
The lacing engine assembly incorporates self-aligning features and snap-fit connections that enable automatic positioning and securing during assembly, reducing the need for precise manual alignment and complex fastening procedures. This self-service design accelerates assembly and reduces the potential for assembly errors.
4Extent of automation
If motorized lacing systems are implemented in footwear, then automated lace tightening function is achieved, but serviceability deteriorates
Solution Approach 1:
The system is segmented into serviceable modules: the lacing engine assembly can be independently removed from the footwear platform, and the lace cables are separate replaceable components. This modular segmentation enables targeted repair of only the malfunctioning component (lacing engine or lace cables) without requiring disassembly or replacement of the entire footwear system, significantly improving serviceability.
Solution Approach 2:
The design allows the expensive lacing engine assembly and footwear platform to be recovered and reused after service, while only the consumable lace cables are discarded and replaced. This extends the service life of the high-cost components and reduces the frequency of expensive replacements, lowering the overall cost of ownership and improving the economic aspect of serviceability.
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 modular design allows for efficient assembly, interchangeability of lacing engines, and effective lace tension management, enhancing performance and comfort while reducing manufacturing costs and improving serviceability.
Implementation Method 1
lacing engines with mechanisms to detect lace cable position and/or lace cable tensions
Implementation Method 2
optical sensors to detect lace position and tension
Implementation Method 3
electrode impedance measurement
Data Source
AI summary
The specification discusses various lacing engine configurations for use in an automated footwear platform. For example, lacing engines with mechanisms to detect lace cable position and/or lace cable tensions are discussed. In an example, the lacing engine can include a housing, a lace spool and a detection mechanism. The lace spool can be at least partially disposed within the housing, and be adapted to collect a portion of the lace cable in response to rotation in a first direction during tightening of the footwear platform. The detection mechanism can detect a state of the lace cable manipulated by the lacing engine.