Tensioning Device

Lace-based tensioning systems are commonly used in a variety of applications, including footwear, orthopedic devices, and wearable equipment, to secure components or adjust fit. These systems typically rely on a flexible tensioning element—such as a lace, cable, or wire—that is wound around a spool or routed through guides and tightened using a manual or mechanical actuator. The ability to apply and maintain consistent tension is critical to the performance and comfort of the underlying device.

However, conventional lace tensioning mechanisms often suffer from several limitations. Many designs incorporate numerous moving parts, which can increase manufacturing complexity and cost. The presence of multiple interacting components also introduces more potential points of failure, particularly in environments where dirt, moisture, or mechanical stress are present. Additionally, some systems lack modularity, making them difficult to repair or replace when damaged. These drawbacks can compromise the reliability, durability, and user experience of the overall system.

Moreover, conventional lace tensioning devices may not hold tension properly, especially if the internal components wear down. And although some makers of tensioning devices offer repair kits, replacing internal components like the spool or cable can be daunting due to the intricate routing and housing design. Accordingly, there is a need for a tensioning device with a simplified design and modular characteristics that enable components of the tensioning device to be easily replaced in instances of damage or malfunction.

Disclosed are embodiments of a tensioning device comprising an actuation member and a housing. The actuation member may be configured to adjust the tension of a tensioning element and may include a spool for winding a portion of a tensioning element and a knob connected to the upper end of the spool. The tensioning device may be actuated by rotating the knob to wind the tensioning element onto the spool. The housing may be configured to receive the actuation member and may include a base and an annular wall extending upward from the base. The base and annular wall may form an interior space configured to receive the spool of the actuation member. A first aperture formed in the annular wall may provide access between the interior space and the exterior surface of the annular wall.

In some aspects, the techniques described herein relate to a tensioning device including: a knob configured to adjust tension of a tensioning element, the knob including a set of tabs; a spool for winding a portion of the tensioning element about a first rotational axis; and a housing configured to receive the spool and connected with the knob, the housing including an annular wall extending upward from a base and further including a set of teeth defining a first locking profile; wherein the set of tabs of the knob are configured to displace the spool about the first rotational axis; and wherein the first locking profile is configured to interlock with at least one second locking profile of the tensioning device arranged to prevent rotation of the knob relative to the housing and further arranged maintain tension in the tensioning element under load. Advantageously, the interlocking of the first locking profile with the second locking profile properly holds tension of the tensioning element wrapped around the spool. The simplified design of the tensioning device allows for easy replacement of the spool tensioning element without requiring an intricate routing of the tensioning element through various components of the tensioning device.

The tensioning device can further include a ratchet for incrementally adjusting rotation of the spool about the first rotational axis, the ratchet including one or more levers connected by at least one resilient member, wherein each lever includes one or more prongs defining the at least one second locking profile to interlock with the set of teeth and a shoulder to engage with the tabs. Advantageously, the ratchet provides additional modularity to the tensioning device by being easily replaceable. The ratchet is designed to precisely fit together with the spool and knob to create a durable and reliable interconnection. However, should the at least one second locking profile begin to wear out, replacement of the ratchet is user-friendly and straightforward.

The knob can further include a set of elongated grooves configured to engage with a set of shafts of the spool to incrementally shift the prongs between the set of teeth in a first direction about the first rotational axis. In some aspects, the set of shafts is formed on an upper portion of the spool and is further formed offset and parallel to the first rotational axis. The tabs can be configured to engage with the shoulders of the ratchet for rotating the levers about the shafts of the spool to incrementally shift the prongs between teeth in a second direction about the first rotational axis. Because the knob is designed to interact with both the ratchet and the spool, the distribution of tightening and loosening functions between the ratchet and the spool can help extend the lifetime of the device and can also be used to determine which part of the tensioning device might need replacement.

The tensioning device can further include a range limiting member configured to permit rotation of the spool about the first rotation axis and restrict rotation of the spool in an opposite direction about the first rotation axis. The range limiting member can include an arm arranged within a cavity of the spool and configured to engage with a gutter of the housing to restrict rotation of the spool in the opposite direction.

In some aspects, the techniques described herein relate to a tensioning device including: a knob configured to adjust tension of a tensioning element, the knob including a set of tabs; a spool for winding a portion of the tensioning element about a first rotational axis; and a housing configured to receive the spool and connected with the knob, the housing including an annular wall extending upward from a base and further including a set of teeth defining a first locking profile; a ratchet for incrementally adjusting rotation of the spool about the first rotational axis, the ratchet being positioned between the knob and the spool; wherein the set of tabs of the knob are configured to displace the spool about the first rotational axis; and wherein the first locking profile is configured to interlock with at least one second locking profile of the tensioning device to prevent rotation of the knob relative to the housing and maintain tension in the tensioning element under load.

The ratchet can include a set of arms, a set of levers that are rotatably connected to the set of arms, and a resilient member configured to bias the set of levers against the teeth of the housing. Each lever can be rotatably connected to each arm by a protrusion arranged offset and parallel to the first rotational axis. In some aspects, each lever includes prongs defining the at least one second locking profile to interlock with the set of teeth. The tabs can be configured to engage with the arms of the ratchet for rotating the levers and incrementally shifting the prongs between teeth in a first direction about the first rotational axis, and the tabs can further be configured to engage with the levers of the ratchet for rotating the levers and incrementally shifting the prongs between teeth in a second direction about the first rotational axis.

In some aspects, the techniques described herein relate to a tensioning device including: a knob configured to adjust tension of a tensioning element; a spool for winding a portion of the tensioning element about a first rotational axis; and a housing configured to receive the spool and connected with the knob, the housing including an annular wall extending upward from a base and further including a first locking profile; wherein rotation of the knob displaces the spool about the first rotational axis; and wherein the first locking profile is configured to interlock with a second locking profile of the tensioning device to prevent rotation of the knob relative to the housing and maintain tension in the tensioning element under load, the second locking profile is a complement of the first locking profile; wherein the first locking profile and the second locking profile are axially arranged about the first rotational axis. The tensioning device can further include a biasing element arranged to bias the first locking profile against the second locking profile, wherein the biasing element is an elastic spring arranged between the spool and the knob.

The components may be injection molded, and various features may be combined, such as the spool being integrated with the knob, or the base including a spool or other components, or whatever may be the simplest manner to integrate components to reduce parts and simplify the construction of the tensioning device. However, the disclosure does not limit any such combination of components, and the construction may be of any combination described herein. Further, due to the simplicity and minimal componentry, parts of the tensioning device may be molded or formed with portions of the component upon which the tensioning device is secured. For example, a base of the tensioning device may be molded or otherwise formed integrally with a component upon which the tensioning device is secured so that a single piece consisting of the component and a part (such as the base but not limited) of the tensioning device are formed together.

These and other features, aspects, and advantages of the present disclosure will be better understood in the following description, appended claims, and accompanying drawings.

The term “tensioning resistance” may refer to the tension that the tensioning device resists from the tensioning element before unwinding it. It may also refer to the maximum force the tensioning device exerts against a user during winding.

The “tensioning element” may refer to a cable, cord, lace, wire, fiber, or other elongated element capable of being wound and unwound from a spool. A “spool” has its ordinary meaning as preferably a cylindrical device upon which a tensioning element may be wound. A “knob” is an attachment that can be used to articulate or actuate the spool for winding and unwinding the tensioning element.

The term “clockwise direction” may refer to a direction the knob may rotate relative to the housing when viewing the knob from above (see). The term “counter-clockwise direction” may refer to a direction opposite the clockwise direction.

The term “underlying device” may refer to a device to which the tensioning device may be attached. The underlying device may be a device or garment, such as a prosthetic device, a shoe or boot, sports equipment, protective equipment (e.g., a helmet), industrial equipment, outdoor equipment, clothing apparel (such as a coat), or another underlying device.

The term “interlock” may refer to a relationship in which two interlocked components do not rotate relative to one another along one or more axes.

A better understanding of different embodiments of the disclosure may be had from the following description read with the accompanying drawings in which like reference characters refer to like elements. While the disclosure is susceptible to various modifications and alternative constructions, certain illustrative embodiments are in the drawings and are described below. It should be understood, however, that there is no intention to limit the disclosure to the embodiments disclosed; but on the contrary, the intention covers all modifications, alternative constructions, combinations, and equivalents falling within the spirit and scope of the disclosure.

Disclosed are embodiments of a tensioning device that may be used to close or narrow an opening. The tensioning device may be disposed of or incorporated into an underlying device, such as an orthopedic or prosthetic device or system. Exemplary patents incorporating a tensioning device may be found in U.S. Pat. No. 9,125,730, granted 8 Sep. 2015; U.S. Pat. No. 10,543,112, granted 28 Jan. 2020; U.S. Pat. No. 10,765,180, granted 8 Sep. 2020; U.S. Pat. No. 11,234,850, granted 1 Feb. 2022; U.S. Pat. No. 11,529,250, granted on 20 Dec. 2022; U.S. Pat. No. 11,253,384, granted on 22 Feb. 2022; each of the aforementioned exemplary patents is incorporated herein by reference.

The tensioning device disclosed herein has the benefit of a simplified design compared to other devices in the prior art. Such a simplified design may decrease the complexity of the manufacturing process, with fewer parts being needed to manufacture and assemble the device. The simplified design may also involve fewer moving parts and connections between parts, which may increase the durability of the device. The tensioning device may also be modular, such that the tensioning device may be easily removed and replaced in instances of damage or malfunction.

shows a tensioning devicedisposed on a component or shell of an orthopedic device, as in U.S. Pat. No. 11,253,384. For example, the tensioning devicecan be disposed on a component and configured, in combination with the tensioning element, to secure the component to a limb of a user by tightening the tensioning element secured to one or more points on the component to bring portions of the orthopedic in proximity with the limb of the user.

The tensioning devicemay be used in other applications, such as to secure footwear (e.g., tighten shoelaces or wiring), sports equipment (e.g., protective gear such as helmets or shoulder pads), protective equipment, or other garments to the user. Indeed, the tensioning device is not limited to being used in an orthopedic or prosthetic device and may be used in any device to open, close, tighten, or loosen one component relative to another object or other component.

illustrate the tensioning device. The tensioning devicemay comprise a knob or actuation memberconfigured to adjust the tension of a tensioning element(seen in) and a housingconfigured to receive the actuation member. The actuation membermay comprise a spoolonto which a portion of the tensioning elementis wound and a knobattached to the spoolconfigured to be rotated by a user to wind the tensioning elementonto the spool. The tensioning elementis a cable or line anchored to and wound about the spool, and one skilled in the art will understand that said tensioning elementcan be used in all embodiments of the present disclosure and is shown in the exemplary figures.

The housingmay comprise a generally horizontally extending baseand an annular wallextending upward from base. The annular wallmay define an interior spacehaving a closed end at the baseand an open end opposite the base. The interior spacemay be configured to receive the spoolof the actuation memberand the tensioning elementonto which it is wound, with the annular wallproviding a rounded surface within which the spoolof the actuation membermay rotate. The annular wallmay further comprise a first apertureto provide access between the interior spaceand the exterior surfaceof the annular wall.

The actuation memberand the housingmay be formed from the same or similar materials. The actuation memberand the housingmay be formed from a plastic, a metallic (e.g., brass, aluminum, or steel), or a composite material. For example, the actuation memberand the housingmay comprise acetal polyoxymethylene, glass-filled nylon materials, or other materials. The actuation memberand housingmay be formed as a result of an additive manufacturing process or an injection molding process.

The tensioning elementmay comprise an elongated flexible member and may be formed of a material with a high modulus of elasticity and a high tensile strength or any other suitable material. The tensioning elementmay comprise a polymeric (e.g., nylon or other plastics) or metallic material. For example, the tensioning elementmay comprise high-modulus polyethylene fibers or steel wire. In some embodiments, the tensioning elementmay comprise a braided material. In some embodiments, the tensioning elementmay comprise a molded monofilament polymer. The diameter and shape of the tensioning element may also vary depending on the application. For example, the transverse cross-sectional shape may be circular, triangular, square, oval, etc. In some embodiments, the tensioning elementmay comprise a strap having a greater width than thickness. In some embodiments, the tensioning devicemay be configured to wind multiple tensioning elements.

shows a cross-sectional view of the tensioning devicethat more clearly illustrates the interior spaceformed by the annular wallsof the housing. A cross-section of the actuation memberis shown, the actuation membercomprising the knoband the spool. The spoolmay comprise a winding portionfor receiving a portion of the tensioning element, an upper flange, and a lower flange, the upper and lower flanges,extending radially outward from the upper and lower ends, respectively, or the winding portionof the spooland configured to direct the tensioning elementonto winding portion. The winding portionand upper and lower flanges,of the spoolmay comprise rounded surfaces to direct the tensioning elementtowards the middle of the spoolduring winding of the tensioning device.

The knobmay be generally disc-like in form, such that the knobhas a generally circular profile when viewed from above. The knobmay comprise other profiles, such as a polygonal (e.g., triangular, square, pentagonal, or hexagonal profile) or oblong profile. The knobmay be configured to be gripped and rotated by a user. The knobmay comprise a textured surfaceto facilitate gripping of the knobby the user.

As illustrated, the textured surfaceof the knobmay comprise a plurality of recessesdisposed radially about the edge portionof the knob. Each recessmay comprise a cutout having a circular or other shape to enable the knobto be easily gripped by the user. In some embodiments, the textured surfaceof the knobmay comprise a knurled or scalloped surface or may comprise a plurality of protrusions (e.g., bumps) extending from the surface of the knobthat may provide a user with a tactile feel and facilitate gripping of the knob. In other embodiments, the knobmay not have a textured surfacebut may comprise a smooth surface.

The lower end of the knobmay be connected to the upper end of the spool, such that rotation of the knobby a user is transmitted to rotate the spool. As shown, the spooland knobmay be integrally formed, such that the spooland knobform a single piece. In other embodiments, the spooland the knobmay comprise multiple distinct components. This may be done to facilitate manufacturing of the actuation member. In such instances, the upper end of the spoolmay be bonded or otherwise connected to the knob.

The tensioning elementmay be connected to the tensioning deviceby threading the first end of the tensioning elementthrough the apertureinto the interior spaceof the housing. The first end of the tensioning elementmay then be fixed to the winding portionof the spoolor other portion of the actuation member. In some embodiments, the first end of the tensioning element, after being threaded through aperture, may be threaded through a second aperture. The first end of the tensioning elementmay then be attached to the upper surfaceof the knobor otherwise prevented from returning through the second aperture.

For example, the first end of the tensioning elementmay be bonded to the upper surfaceof the knob. In other embodiments, a fitting (e.g., a crimped bead) may be attached to the first end of the tensioning elementto prevent the first end of the tensioning element from returning through the second aperture. In some embodiments, a knot may be formed in the first end of the tensioning elementto perform the same function as the fitting.

The above methods of fixing the first end of the tensioning elementto the upper surfaceof the knobmay beneficially enable the user to cut or shorten the first end of the tensioning elementaccording to the needs of the user and then configure the first end of the tensioning elementto prevent the first end of the tensioning elementto pass through the second aperture, to enable the length of the tensioning elementto be quickly and/or easily adjusted.

The second end of the tensioning elementmay be threaded through one or more guides (e.g., loops) disposed on a side opposite the opening from the side on which the tensioning deviceis located. The second end of the tensioning elementmay then be attached to the underlying device, such that as the tensioning deviceis actuated (by rotating the knob), the tensioning elementis tightened to shorten the length of the tensioning elementbetween the second end of the tensioning elementand the tensioning device. In some embodiments, the second end of the tensioning elementmay be fixed to the housingof the tensioning device, such as at an additional aperture or fixture configured to receive the second end of the tensioning device.

In other embodiments, the second end of the tensioning elementmay be fixed to the actuation member, as will be described more fully below. In this manner, the tensioning devicemay be provided as a modular component that may be fixed or secured (e.g., sewn) to the underlying device. This may enable the tensioning deviceto be easily replaced in case of damage or malfunction.

The housingmay comprise a rounded bossprotruding from the baseinto the interior spaceconfigured to interface with the actuation member. The spoolmay comprise a recessconfigured to receive the boss, and the spoolis configured to rotate about the boss. The rounded bossmay preferably extend through the center of the interior spaceto center the spoolwithin the interior space.

The actuation memberand housing may interface at a lower surfaceof the knoband an upper surfaceof the annular wall. The lower surfaceof the knobmay comprise a first locking profileconfigured to interlock with a second locking profileof the upper surfaceof the annular wall, such that the tension imparted to the tensioning elementwhen turning the knobis maintained as the first locking profilepushes against the second locking profile. In this manner, the first and second locking profiles,prevent rotation of the actuation memberrelative to the housingin a direction that loosens the tensioning element.

A user may choose a first direction to rotate the knob—either a clockwise direction CW or a counter-clockwise direction CCW when viewed from above, as seen in—to tighten the tensioning element. In the embodiment illustrated in, a user may beneficially select the first direction to be in the clockwise direction CW as the tensioning elementmay be more easily wound onto the spoolas a result of the apertureextending from the exterior surfaceof the annular wallto the interior spacein a generally clockwise direction. However, the tensioning elementmay be optionally wound in the counter-clockwise direction CCW. The tensioning elementmay be more easily wound in the clockwise direction CW or the counter-clockwise direction CCW depending on the location of the apertureon the exterior surfaceof annular wall.

The first and second locking profiles,may be configured to resist tension from the tensioning elementexerted on the actuation memberand to prevent the tensioning elementfrom unwinding the tensioning device. However, the first and second locking profiles,may be configured such that a force in the clockwise CW or counter-clockwise CCW directions greater than that of the tension in the tensioning element(e.g., from the hand of a user) may rotate the knob, allowing a user to actuate the tensioning device. The first and second locking profiles,may be tailored depending on the tensioning elementused with the tensioning device.

During rotation of the knobby the user, the actuation membermay separate from the housing, either as a result of the shape of the first and second locking profiles,or to facilitate winding of the tensioning device. This may create a gap between the lower surfaceof the knoband the upper surfaceof the annular wall. The knobmay be formed such that the edge portionof the knobextends over the first and second locking profiles,to prevent debris from entering the interior spaceof the tensioning devicethrough the first and second locking profiles,. The edge portionmay also beneficially prevent debris from catching between the first and second locking profiles,to prevent effective interlocking of the tensioning deviceor prevent increased wear of the first and second locking profiles,. The height H of the edge portionof the knobmay be sufficient to cover the first and second locking profiles,during the maximum separation of the actuation memberfrom the housingduring operation of the tensioning device.

shows a top cross-sectional view of the tensioning deviceviewed along plane A-A and more clearly illustrates the first and second locking profiles,of the tensioning device. The first locking profilemay have a complementary shape to the second locking profile, such that when the tensioning deviceis not actuated by the user a minimal or no gap is formed between the first and second locking profiles,, thereby maximizing the surface contact between the first and second locking profiles,to increase the tension resistance of the tensioning device. In other embodiments, the shape of the first locking profilemay not complement that of the second locking profile, such that a gap may be formed and the surface contact between the first and second locking profiles,is not maximized and decreasing the tension resistance of the device. The amount of surface contact along the first and second locking profiles,may be tailored to adjust the tension resistance of the tensioning deviceaccording to the user's needs.

The first and second locking profiles,may comprise teeth, the teethof the housingbeing configured to interlock with teethof the knob. The tensioning resistance of the tensioning devicemay depend on the number of teethdisposed over the first and second locking profiles,. The first or second locking profiles,may individually or in combination comprise a range of four to thirty teeth, six to twenty teeth, eight to fifteen teeth, ten to twelve teeth, or a range having any two of the preceding as endpoints.

illustrate exemplary plan views of a portion of the second locking profileextended over a plane, wherein a skilled person would understand that the shape of the first locking profilemay complement the second locking profiles,,illustrated. Concerning, each of the teethmay comprise a first angled surfaceand a second angled surfacethat meet at an apexof each of the teeth. The first angled surfacemay be set at a first angle Ameasured relative to the circumference C of the annular wall, and the second angled surfacemay be set at a second angle Ameasured relative to the circumference C of the annular wall.

As the knobis rotated in a direction from the first angled surfaceto the second angled surface, the knobis lifted by sliding up the incline of the first angled surfaceuntil the lower-most portion of the knobmeets the apex, increasing the size of the gap between the first and second locking profiles,, from which point as the knobcontinues to be rotated the knob descends along the incline of the second angled surface, reducing the size of the gap. A similar increase and decrease in the gap size may occur when the knobis rotated in the opposite direction, as described above.

The tensioning resistance of the tensioning devicemay depend on the magnitude of the first and second angles A, A. The magnitude of the first and second angles A, Amay be in a range of approximately above zero to approximately 60 degrees, or approximately 10 degrees to approximately 50 degrees, or approximately 15 degrees to approximately 45 degrees, or approximately 20 degrees to approximately 40 degrees, or may be approximately 30 degrees, or may be in a range with any two of the preceding as endpoints. As shown in, the first and second angles A, Aof the first and second angled surfaces,may be approximately equal, such that the tensioning resistance is approximately equal in both the clockwise CW and counter-clockwise directions, the first angled surfaceextending along the annular walland having a first width Wapproximately equal to the second width Wof the second angled surface

illustrates another embodiment of the second locking profilewherein the first angled surfaceof each of the teethhas a first angle Asmaller than the second angle Aof the second angled surfaceand such that the width Wof the first angled surfaceis greater than the width Wof the second angled surface. Because the first angle Ais smaller than the second angle A, the second locking profile will have a tensioning resistance smaller in a first direction from the first angled surfaceto the second angled surfacethan in a second direction opposite the first direction (i.e., from the second angled surfaceto the first angled surface). This configuration may aid a user in tightening the tensioning devicein the first direction while retaining greater tensioning resistance in the second direction. The tensioning resistance of the tensioning devicein a first direction compared to the second direction may be at a 1.5:1 ratio, a 2:1 ratio, a 3:1 ratio, a 5:1 ratio, a 10:1 ratio, or at a ratio within a range of any of the preceding as endpoints.

illustrates an additional embodiment of the second locking profile, wherein the second angle Aof the second angled surfaceof each of the teethis oriented at a perpendicular or near perpendicular angle to the circumference C, the second angled surfaceextending in a generally direct manner from the annular walltowards the knob. Such a locking profilemay maximally increase the tensioning resistance of the tensioning devicein the second direction (i.e., from the second angled surfacetowards the first angled surface) while enabling the rotation of the knobin the first direction (i.e., from the first angled surfacetowards the second angled surface). In this embodiment of the second locking profile, the knob may not be rotated in the second direction unless the first locking profileof the knob is elevated above the second locking profile

In some embodiments, the first locking profilemay comprise one or more pawls configured to interlock with the teethof the second locking profile. The pawls may be configured to prevent the knobfrom rotating in a direction to decrease the tension of the tensioning elementwhile the pawls contact the teethof the second locking profile. The tensioning devicemay comprise a release mechanism configured to elevate the first locking profileabove the second locking profile(and thus lifting the whole of the actuation member), such that the first and second locking profiles are not interlocked and enabling the user to freely increase the size of the opening or pull on the tensioning elementto unwind the tensioning device, enabling quick release of the tensioning element.

In one embodiment, the release mechanism may comprise a lever pivotably attached to the housingand configured to lift the lower endof the spool. In other embodiments, the release mechanism may comprise a mechanism wherein the knobis raised relative to the spool. For example, the connection between the knoband the spoolmay comprise a push spring, wherein when a user may push down on the knobto actuate the push spring and thereby lift the knobto an elevated position relative to the spool.