Tension limiting mechanisms for closure devices and methods therefor

1. A reel for use with a lacing system for tightening an article comprising:

a housing having an interior region;

a spool positioned within the interior region of the housing and rotatable relative thereto, the spool having an annular channel formed therein;

a knob rotatable relative to the housing and operably coupled with the spool to cause the spool to rotate within the interior region of the housing;

a tension member coupled with the spool so as to be tensioned by winding the tension member around the spool's annular channel upon rotation of the knob;

a pawl mechanism including at least one pawl arm that engages with teeth in a ratchet like manner as the knob is rotated in a tightening direction; and

a tension control mechanism that is operationally coupled with the pawl mechanism so that while the at least one pawl arm remains engaged with the teeth, the tension control mechanism enables tensioning of the tension member by rotation of the knob in the tightening direction until a tension threshold is achieved, after which further rotation of the knob in the tightening direction does not cause further tensioning of the tension member; and

allows rotation of the spool within the housing's interior region upon tensioning of the tension member from the article.

2. The reel of claim 1 , further comprising an indicator that visually indicates the tension threshold.

3. The reel of claim 1 , wherein the tension control mechanism comprises:

a first mechanism that enables tensioning of the tension member by rotation of the knob until the tension threshold is achieved; and

a second mechanism that enables rotation of the spool upon tensioning of the tension member from the source other than the knob.

4. The reel of claim 3 , wherein the second mechanism comprises a non-linear interface between a top surface of the spool and a bottom surface of the tension control mechanism, wherein the non-linear interface transfers a rotational force from the knob to the spool until the tension threshold is achieved, and wherein the non-linear interfaces allows slippage of the top surface of the spool and the bottom surface of the tension control mechanism after the tension threshold is achieved to limit additional tensioning of the tension member.

5. The reel of claim 4 , wherein the bottom surface of the tension control mechanism and the top surface of the spool have a wave-like or sinusoidal shape.

6. The reel of claim 4 , wherein the non-linear bottom surface of the tension control mechanism and the non-linear top surface of the spool are configured to frictionally engage.

7. The reel of claim 1 , wherein the tension control mechanism comprises a single mechanism.

8. The reel of claim 1 , wherein the tension control mechanism comprises:

one or more cantilever arms that extend from a main body of the tension control mechanism and that engage with corresponding teeth of a spool driving mechanism to enable tensioning of the tension member by rotation of the knob until the tension threshold is achieved; and

one or more torque control members that adjust the tension threshold by adjusting a flexibility of the one or more cantilever arms.

9. The reel of claim 8 , wherein the one or more torque control members are adjustable by a user to adjust the tension threshold.

10. The reel of claim 1 , wherein the housing comprises an open top end and an open bottom end.

11. A device for tightening an article comprising:

a housing having an interior region;

a spool rotatably positioned within the interior region of the housing;

a knob that is coupled with the housing so that the knob is rotatable in a tightening direction relative to the housing;

a tension member coupled with the spool and configured to be tensioned upon rotation of the spool via rotation of the knob in the tightening direction;

a pawl mechanism that is operationally coupled with the knob, the pawl mechanism including at least one pawl arm that engages with teeth in a ratchet like manner as the knob is rotated in the tightening direction; and

a tension limiting mechanism that is operationally coupled with the pawl mechanism so that while the at least one pawl arm remains engaged with the teeth, the tension limiting mechanism enables the tension member to be tensioned via rotation of the knob in the tightening direction until a tension threshold is achieved, after which further rotation of the knob in the tightening direction does not further substantially tension the tension member.

12. The device of claim 11 , further comprising a control mechanism that allows the tension member's tension to be substantially maintained upon tensioning of the tension member from the article.

13. The device of claim 12 , wherein the control mechanism is disposed axially below the pawl mechanism.

14. The device of claim 12 , wherein the control mechanism comprises a non-linear bottom surface that frictionally engages with a non-linear top surface of the spool to transfer rotational forces between the control mechanism and spool and thereby tension the tension member until the tension threshold is achieved, and to allow slippage of the spool relative to the control mechanism after the tension threshold is achieved so as to limit additional tensioning of the tension member.

15. The device of claim 14 , wherein the bottom surface of the control mechanism and the top surface of the spool have a wave-like or sinusoidal shape.

16. The device of claim 14 , wherein the non-linear bottom surface of the control mechanism and the non-linear top surface of the spool are configured to frictionally engage.

17. The device of claim 11 , wherein the tension limiting mechanism is disposed axially above the pawl mechanism.

18. The device of claim 11 , further comprising an indicator having indicia representative of a set tension threshold.

19. The device of claim 11 , wherein the tension limiting mechanism further comprises:

at least one cantilever arm that extends from a main body of the tension limiting mechanism and that engages with corresponding teeth of a spool driving mechanism to enable tensioning of the tension member until the tension threshold is achieved; and

at least one torque control member that adjusts the tension threshold by adjusting a flexibility of the at least one cantilever arm.

20. The device of claim 19 , wherein the at least one cantilever arm is configured to axially engage with the corresponding teeth of the device.

21. The device of claim 19 , wherein the at least one cantilever arm is configured to radially engage with the corresponding teeth of the device.

22. The device of claim 19 , wherein the at least one torque control member is adjustable by a user to adjust the tension threshold.

23. The device of claim 19 , wherein the housing comprises an open top end and an open bottom end.

24. A method for assembling a device for tightening an article comprising:

providing a housing having an interior region;

positioning a spool within the interior region of the housing so that the spool is rotatable within the interior region of the housing;

operably coupling a knob with the housing so that the knob is rotatable in a tightening direction relative to the housing;

coupling a tension member with the spool so that the tension member is tensionable upon rotation of the spool via rotation of the knob in the tightening direction;

operably coupling a pawl mechanism with the knob, the pawl mechanism including at least one pawl arm that engages with teeth in a ratchet like manner as the knob is rotated in the tightening direction; and

operably coupling a tension limiting mechanism with the pawl mechanism and spool so that while the at least one pawl arm remains engaged with the teeth, the tension limiting mechanism enables the tension member to be tensioned via rotation of the knob in the tightening direction until a tension threshold is achieved, after which further rotation of the knob in the tightening direction does not further tension the tension member.

25. The method of claim 24 , further comprising providing the device with an indicator having indicia representative of a set tension threshold.

26. The method of claim 24 , wherein the tension limiting mechanism further comprises:

at least one cantilever arm that extends from a main body of the tension limiting mechanism and that engages with corresponding teeth of a spool driving mechanism to enable tensioning of the tension member until the tension threshold is achieved; and

at least one torque control member that adjusts the tension threshold by adjusting a flexibility of the at least one cantilever arm.

27. The method of claim 24 , wherein the tension limiting mechanism is further configured to allow the tension member's tension to be substantially maintained upon tensioning of the tension member from the article.

28. The method of claim 27 , wherein the tension limiting mechanism is disposed axially below the pawl mechanism.

29. The method of claim 28 , wherein the tension limiting mechanism comprises a non-linear bottom surface that frictionally engages with a non-linear top surface of the spool to transfer rotational forces between the tension limiting mechanism and spool, and wherein the tension limiting mechanism allows the spool to slip relative to the tension limiting mechanism after the tension threshold is achieved to limit additional tensioning of the tension member.

30. The method of claim 24 , wherein the housing comprises an open top end and an open bottom end.