Motorized tensioning system

1. A method for making a motorized tensioning device, comprising:

coupling a motor to a gear reduction system, wherein the motor is configured to drive the gear reduction system;

connecting a spool connected to the gear reduction system, the spool configured to wind a tensioning member, wherein the spool is configured to rotate in a first rotational direction to tighten the tensioning member rotate in a second rotational direction opposite the first rotational direction to loosen the tensioning member;

coupling a torque transmitting system to the spool, the torque transmitting system configured to substantially prevent the spool from driving the motor; and

wherein the torque transmitting system is configured to transmit torque from a gear of the gear reduction system to the spool.

2. The method according to claim 1 , wherein connecting the motor to the gear reduction system and the spool to the gear reduction system allows the motorized tensioning device to operate in an incremental loosen mode where tension in the tensioning member is reduced by an incremental amount and in a fully loosen mode where tension in the tensioning member is fully released.

3. The method according to claim 1 , wherein coupling the torque transmitting system to the spool and includes disposing at least a portion of the torque transmitting system between the gear reduction system and the spool.

4. The method according to claim 1 , wherein coupling the torque transmitting system to the spool allows the spool to rotate in the first rotational direction as the torque transmitting system transmits torque from the gear reduction system to the spool.

5. The method according to claim 1 , wherein coupling the torque transmitting system to the spool prevents the spool from transmitting torque to the gear reduction system when the spool rotates in the second rotational direction.

6. The method according to claim 1 , wherein the torque transmitting system includes a ratcheting assembly mounted on a shaft with a threaded end and coupling the torque transmitting system to the spool includes coupling the spool to the shaft at the threaded end.

7. A method for adjusting a tensioning member in an article of footwear, comprising:

operating a torque transmitting system in an incremental tighten mode where torque generated by a motor is used to rotate a spool in a first rotational direction and thereby tighten the tensioning member incrementally;

operating the torque transmitting in an incremental loosen mode where the motor rotates the spool in a second rotational direction opposite the first rotational direction to lessen the tension in the tensioning member incrementally; and

operating the torque transmitting system in a full loosen mode in which substantially no torque is transmitted from the torque transmitting system to the spool.

8. The motorized tensioning device according to claim 7 , wherein a secondary winding assembly is connected to the spool and wherein operating the torque transmitting system in the incremental tighten mode drives the spool in the first rotational direction when there is slack in the tensioning member.

9. The motorized tensioning device according to claim 8 , wherein the secondary winding assembly prevents the tensioning member from tangling on the spool.

10. The motorized tensioning device according to claim 8 , wherein the secondary winding assembly operates independently of the motor.

11. The motorized tensioning device according to claim 7 , wherein the torque transmitting system includes a ratcheting assembly configured to engage a first end of the spool and a rotation control assembly capable of engaging a second end of the spool.

12. The motorized tensioning device according to claim 11 , wherein operating in the incremental loosen mode includes clamping and unclamping the ratcheting assembly to the first end of the spool while the rotation control assembly is engaged with the second end of the spool.

13. The motorized tensioning device according to claim 12 , wherein the ratcheting assembly, the spool and the rotation control assembly are mounted on a shaft and wherein the spool and the shaft are rotatably locked together while operating in the incremental loosen mode when the rotation control assembly is engaged with the second end of the spool.

14. A method of making a motorized tensioning device for adjusting a tensioning member in an article of footwear, comprising:

coupling a motor to a gear reduction system, wherein the motor is configured to drive the gear reduction system;

a spool configured to wind a tensioning member, wherein the spool can rotate in a first rotational direction for tightening the tensioning member and wherein the spool can rotate in a second rotational direction opposite the first direction for loosening the tensioning member;

coupling a torque transmitting system to the gear reduction system and the spool, the torque transmitting system configured to transmit torque from the gear reduction system to the spool so that torque generated by the motor can rotate the spool in the first rotational direction;

rotatably mounting the spool to a shaft including a threaded end;

mounting a ratcheting assembly onto the threaded end of the shaft, wherein the ratcheting assembly is disposed between the gear reduction system and a first end of the spool, and where the ratcheting assembly transmits torque from the gear reduction system to the first end of the spool;

mounting a rotation control assembly onto the shaft, the rotation control assembly being associated with a second end of the spool;

wherein the ratcheting assembly is configured to transmit torque to the first end of the spool by rotating on the threaded end of the shaft and clamping against the first end of the spool; and

wherein the rotation control assembly is configured to lock the shaft and the spool together so that shaft and the spool cannot rotate independently.

15. The motorized tensioning device according to claim 14 , wherein the ratcheting assembly includes a pawl member and a ratchet housing.

16. The motorized tensioning device according to claim 15 , wherein a gear of the gear reduction system, the pawl member and an end of the spool are configured to be clamped together to drive the spool.

17. The motorized tensioning device according to claim 14 , wherein the torque transmitting system is configured to be operated in a first mode to incrementally loosen tension and in a second mode to fully loosen tension.

18. The motorized tensioning device according to claim 14 , wherein the rotation control assembly includes an engagement plate with at least one pin and further comprising inserting the at least one pin into an alignment hole on the spool.

19. The motorized tensioning device according to claim 18 , wherein the shaft includes a flange portion and wherein the flange portion is disposed between the spool and the engagement plate.

20. The motorized tensioning device according to claim 14 , wherein the tensioning member is a lace.