Modular Spool for Automated Footwear Lacing
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Solution Overview
Problem
Existing motorized lacing systems for footwear face challenges such as high cost of manufacture, complexity, assembly difficulties, lack of serviceability, and fragile mechanical mechanisms, making them unsuitable for mass production and daily use.
Innovation Solution
A modular footwear platform is developed to accommodate both motorized and non-motorized lacing engines, featuring a robust, serviceable, and interchangeable design. The system includes a housing structure, a modular spool, and a drive mechanism, allowing for retail-level customization and streamlined assembly processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If a motorized lacing system is implemented, then automated tightening function is achieved, but manufacturing cost increases
Solution Approach 1:
The lacing system is divided into modular components: a lacing engine housed in a housing structure, a separate drive mechanism, and interchangeable spools. This segmentation allows each component to be manufactured independently using optimized processes, reducing overall manufacturing complexity and cost while maintaining automated functionality.
Solution Approach 2:
The housing structure is designed to accommodate multiple types of spools and can interface with different drive mechanisms, creating a universal platform that can produce various lacing system configurations. This multi-functionality reduces tooling costs and enables economies of scale in manufacturing.
2Extent of automation
If a motorized lacing system is implemented, then automated tightening function is achieved, but device complexity increases
Solution Approach 1:
By separating the lacing engine from the drive mechanism and using interchangeable spools, the system divides complex functions into manageable modules. Each module has a simplified internal structure, making the overall system easier to understand, manufacture, and service despite maintaining automated functionality.
Solution Approach 2:
The housing structure serves as an intermediary that interfaces between the simple lacing engine and the drive mechanism. This intermediary component provides standardized mounting interfaces and cable routing, simplifying the integration between parts and reducing overall system complexity.
3Extent of automation
If a motorized lacing system is implemented, then automated tightening function is achieved, but assembly difficulty increases
Solution Approach 1:
The system is assembled from pre-manufactured modules: the lacing engine is inserted into the housing structure, the spool is mounted separately, and the drive mechanism is attached as a distinct unit. This modular assembly approach significantly reduces assembly difficulty compared to manufacturing the entire motorized system as a single integrated component.
Solution Approach 2:
Components such as the lacing engine and spool are prepared and pre-assembled before final installation into the housing. Cable routing paths are pre-configured in the housing structure, and mounting interfaces are pre-formed, allowing for quick and easy final assembly without complex field adjustments.
4Extent of automation
If a motorized lacing system is implemented, then automated tightening function is achieved, but serviceability decreases
Solution Approach 1:
The modular architecture allows the lacing engine, spool, and drive mechanism to be independently accessed and serviced. If one component fails, only that specific module needs to be removed and replaced, not the entire motorized system, significantly improving serviceability while maintaining automated function.
Solution Approach 2:
The interchangeable spool design allows worn or damaged spools to be quickly removed and replaced with new or refurbished units. The spool can be discarded as a consumable component while the expensive lacing engine and drive mechanism are retained and reused, improving serviceability and reducing repair costs.
5Extent of automation
If a motorized lacing system is implemented, then automated tightening function is achieved, but mechanical reliability decreases
Solution Approach 1:
By separating the lacing engine from the drive mechanism and using simple mechanical spools, the system reduces the number of complex mechanical interactions. Each module has fewer moving parts and simpler mechanics, improving reliability while maintaining automated tightening capability.
Solution Approach 2:
The housing structure acts as a protective intermediary that shields the lacing engine and cable routing from external damage and contamination. It provides structural support and alignment for the spool and drive mechanism, enhancing mechanical reliability while enabling automated function.
Data Source
AI summary
A footwear lacing apparatus can comprise a housing structure, a modular spool and a drive mechanism. The housing structure can comprising a first inlet, a second inlet, and a lacing channel extending between the first and second inlets. The modular spool can be disposed in the lacing channel and can comprise a lower plate including a shaft extending from the lower plate, and an upper plate including a drum portion. The upper plate can be releasably connected to the lower plate at a connection interface. The drive mechanism can couple with the modular spool and can be adapted to rotate the modular spool to wind or unwind a lace cable extending through the lacing channel and between the upper and lower plates of the modular spool.