Note: Descriptions are shown in the official language in which they were submitted.
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FOOTWEAR HAVING SENSOR SYSTEM
DESCRIPTION
CROSS REFERENCE TO RELATED APPLICATIONS
[0001]
This application claims priority to U.S. Patent Application No. 13/401,914
(published
as U.S. Patent Application Publication No. 20130213145), filed February 22,
2012, U.S. Patent
Application No. 13/401,916, (published as U.S. Patent Application Publication
No. 20130213146),
filed February 22, 2012, and U.S. Patent Application No. 13/401,918 (published
as U.S. Patent
Application No. 2013/0213147), filed February 22, 2012, all of which are
entitled "Footwear Having
Sensor System".
TECHNICAL FIELD
[00021 The present invention generally relates to footwear having a
sensor system and, more
particularly, to a shoe having a force and/or pressure sensor assembly
operably connected to a
communication port located in the shoe.
BACKGROUND
[0003] Shoes having sensor systems incorporated therein are known. Sensor
systems collect
performance data wherein the data can be accessed for later use such as for
analysis purposes. In
certain systems, the sensor systems are complex or data can only be accessed
or used with certain
operating systems. Thus, uses for the collected data can be unnecessarily
limited. Accordingly, while
certain shoes having sensor systems provide a number of advantageous features,
they nevertheless
have certain limitations. The present invention seeks to overcome certain of
these limitations and other
drawbacks of the prior art, and to provide new features not heretofore
available.
BRIEF SUMMARY
100041
The present invention relates generally to footwear having a sensor system.
Aspects of
the invention relate to an article of footwear that includes an upper member
and a sole structure, with a
sensor system connected to the sole structure. The sensor system includes a
plurality of sensors that are
configured for detecting forces and/or pressure exerted by a user's foot on
the sensor.
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[0005] Aspects of the invention relate to a sensor system adapted for use
with an article
of footwear. The sensor system includes an insert member configured to be
inserted into a
foot-receiving chamber of an article of footwear, the insert member including
a first layer and
a second layer, a port connected to the insert and configured for
communication with an
electronic module, a plurality of force and/or pressure sensors on the insert
member, and a
plurality of leads connecting the sensors to the port.
[0006] The system may also include a pathway providing electrical
communication
between the first and second layers. The system may further include a housing
connected to
the insert and configured to support the electronic module in communication
with the port.
The insert may further include at least one additional layer, such as a spacer
layer having
holes aligned with the sensors and/or the pathway to permit engagement of such
components
through the spacer layer.
[0007] According to one aspect, the sensor system includes a first resistor
located on the
first layer and a second resistor located on the second layer, each connected
to one or more of
the leads. The port, the pathway, the sensors, the leads, and the first and
second resistors
form a circuit on the insert member, and the circuit is configured to have a
voltage applied
between a first terminal and a ground located at the port. The first and
second resistors are
arranged in parallel between the first terminal and the ground. Each of the
resistors may
include an inner section connected to a first lead, an outer section connected
to a second lead,
and a bridge extending between the inner section and the outer section and
partially
overlapping both the inner section and the outer section, wherein the resistor
is configured
such that an electronic signal can pass between the first lead and the second
lead through the
inner section, the bridge, and the outer section.
[0008] According to another aspect, the pathway may further include a
substantially
annular stiffener positioned around the pathway on at least one of the first
and second layers,
wherein the stiffener has decreased flexibility compared to the pathway. The
pathway may
additionally or alternately include a first conductive portion on the first
layer and a second
conductive portion on the second layer, wherein the first and second
conductive portions are
in continuous engagement with each other through the hole to provide
electrical
communication between the first and second layers, with the first and second
conductive
portions each having a gap extending therethrough and dividing the first and
second
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conductive portions into separate first and second sections. In this
configuration, the gap may
be elongated and aligned substantially perpendicular to a virtual line
extending between a
front edge of the first metatarsophalangeal sensor and a rear edge of the
fourth
metatarsophalangeal sensor. The pathway in this configuration may constitute
two separate
pathways, on opposite sides of the gap.
[0009] According to another aspect, the spacer layer may include a first
hole aligned with
one of the sensors to permit at least partial engagement between the first and
second contacts
of the sensor through the spacer layer, and may further include a channel
extending from the
hole to a vent in the insert member, wherein the channel permits air to flow
between the first
and second layers from the sensor to an exterior of the insert member, through
the first vent.
The vent may have a selectively permeable closure member positioned to cover
the vent.
Additionally, the vent may be connected to more than one sensor through
additional
channels, and/or the insert may contain a second vent connected to one or more
sensors in a
similar arrangement. An article of footwear incorporating the insert may
include a cavity
within a sole member of the footwear that is located at least partially below
the vent. The
cavity extends laterally from the vent to a distal end located outside a
peripheral boundary of
the insert, such that the cavity is configured to permit the air exiting the
first vent to pass
away from the insert member. Further, a patch of dielectric material may be
connected to one
of the first and second layers and may extend across the channel to be
positioned between the
first and second layers, resisting shorting of one or more conductive members
between the
first and second layers through the channel.
[0010] According to a further aspect, the insert may include an extension
extending into
the well and consolidating the ends of the leads to form the interface, the
extension having a
strip of reinforcing material extending across the ends of the leads. The
extension has a bend
area where the extension bends downwardly at or near a peripheral edge of the
housing and a
depending portion that extends downwardly from the bend area into the well. In
this
configuration, the interface is located on the depending portion within the
well, and the strip
extends transversely across the bend area to provide reinforcement and wear
resistance to the
bend area. The system may also contain an interface assembly that includes a
base member
and a plurality of electrical connectors supported by the base member, where
at least a
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portion of the depending portion is received in the base member and the ends
of the leads
engage the electrical connectors to form the interface.
[0011] According to yet another aspect, the insert includes a first
cut-out on a medial
edge of the insert member and a second cut-out on a lateral edge of the insert
member,
proximate a juncture between the forefoot portion and the midfoot portion. A
width of the
insert defined between the medial and lateral edges is larger in the midfoot
portion than the
width measured between the first and second cut-outs and the width measured at
the heel
portion. The insert may also include a hole in the midfoot portion configured
to receive the
housing, and the hole may make up less than half the width of the midfoot
portion. The insert
may also include other cut-out portions.
[0012] Other aspects of the invention relate to sensor systems that
include various
combinations of the above-discussed features.
[0013] Further aspects of the invention relate to a system that
includes an article of
footwear with a sensor system as described above, with an electronic module
connected to the
sensor system, and an external device configured for communication with the
electronic
module. The module is configured to receive data from the sensors and to
transmit the data to
the external device, and the external device is configured for further
processing the data.
[0014] According to one aspect, the system also includes an accessory
device
connected to the external device, configured to enable communication between
the electronic
module and the external device. The accessory device may also be configured
for connection
to a second external device to enable communication between the electronic
module and the
second external device.
[0014a] Further aspects of the invention relate to a sensor system
comprising: an insert
member configured to be inserted into a foot-receiving chamber of an article
of footwear
below a foot of a user, the insert member having a forefoot portion configured
to be
positioned under a forefoot of the user's foot, a midfoot portion configured
to be positioned
under a midfoot of the user's foot, and a heel portion extending rearwardly
from the midfoot
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portion and configured to be positioned under the user's heel; a port
connected to the insert
member and configured for communication with an electronic module; a plurality
of sensors
formed on the insert member, each sensor configured for detecting pressure
applied to the
sensor by the user's foot, wherein the plurality of sensors includes first and
second sensors
located on the forefoot portion of the insert member and a third sensor
located on the heel
portion of the insert member; and a housing connected to the insert member and
configured to
hold the electronic module, the insert member having a hole in the midfoot
portion configured
to receive the housing, wherein the insert member includes a first cut-out on
a medial edge of
the insert member and a second cut-out on a lateral edge of the insert member,
proximate a
juncture between the forefoot portion and the midfoot portion, wherein a width
of the insert
member defined between the medial and lateral edges is larger in the midfoot
portion than the
width measured between the first and second cut-outs and the width measured at
the heel
portion, and wherein the hole makes up less than half the width of the midfoot
portion.
10014b1 Further aspects of the invention relate to a sensor system
comprising: an insert
member configured to be inserted into a foot-receiving chamber of an article
of footwear
below a foot of a user, the insert member having a forefoot portion configured
to be
positioned under a forefoot of the user's foot, a midfoot portion configured
to be positioned
under a midfoot of the user's foot, and a heel portion extending rearwardly
from the midfoot
portion and configured to be positioned under the user's heel; a port
connected to the insert
member and configured for communication with an electronic module; a plurality
of sensors
formed on the insert member, each sensor configured for detecting pressure
applied to the
sensor by the user's foot, wherein the plurality of sensors includes first and
second sensors
located on the forefoot portion of the insert member and a third sensor
located on the heel
portion of the insert member; and a housing connected to the insert member and
configured to
hold the electronic module, the insert member having a hole in the midfoot
portion configured
to receive the housing, wherein the insert member includes three cut-outs,
each of the cut-outs
being at least partially defined by a concave curvilinear edge defining an arc
of at least 1200
.
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[0014c] Further aspects of the invention relate to an article of
footwear comprising: a
sole structure configured to support a user's foot; an upper structure
connected to the sole
structure to define a foot-receiving chamber; an insert member engaged with
the sole
structure, the insert member having a forefoot portion configured to be
positioned under a
forefoot of the user's foot, a midfoot portion configured to be positioned
under a midfoot of
the user's foot, and a heel portion extending rearwardly from the midfoot
portion and
configured to be positioned under the user's heel; a port connected to the
insert member and
configured for communication with an electronic module; a plurality of sensors
formed on the
insert member, each sensor configured for detecting pressure applied to the
sensor by the
user's foot, wherein the plurality of sensors includes first and second
sensors located on the
forefoot portion of the insert member and a third sensor located on the heel
portion of the
insert member; and a housing connected to the insert member and configured to
hold the
electronic module, the insert member having a hole in the midfoot portion
configured to
receive the housing, wherein the insert member includes a first cut-out on a
medial edge of the
insert member and a second cut-out on a lateral edge of the insert member,
proximate a
juncture between the forefoot portion and the midfoot portion, wherein a width
of the insert
member defined between the medial and lateral edges is larger in the midfoot
portion than the
width measured between the first and second cut-outs and the width measured at
the heel
portion, and wherein the hole makes up less than half the width of the midfoot
portion.
[0014d] Further aspects of the invention relate to an article of footwear
comprising: a
sole structure configured to support a user's foot; an upper structure
connected to the sole
structure to define a foot-receiving chamber; an insert member engaged with
the sole
structure, the insert member having a forefoot portion configured to be
positioned under a
forefoot of the user's foot, a midfoot portion configured to be positioned
under a midfoot of
the user's foot, and a heel portion extending rearwardly from the midfoot
portion and
configured to be positioned under the user's heel; a port connected to the
insert member and
configured for communication with an electronic module; a plurality of sensors
formed on the
insert member, each sensor configured for detecting pressure applied to the
sensor by the
user's foot, wherein the plurality of sensors includes first and second
sensors located on the
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forefoot portion of the insert member and a third sensor located on the heel
portion of the
insert member; and a housing connected to the insert member and configured to
hold the
electronic module, the insert member having a hole in the midfoot portion
configured to
receive the housing, wherein the insert member includes three cut-outs, each
of the cut-outs
being at least partially defined by a concave curvilinear edge defining an arc
of at least 120 .
[0015] Still other features and advantages of the invention will be
apparent from the
following specification taken in conjunction with the following drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side view of a shoe;
FIG. 2 is an opposed side view of the shoe of FIG. 1;
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FIG. 3 is a top perspective view of a sole of a shoe (having a shoe upper
removed and
a foot contacting member folded aside) incorporating one embodiment of a
sensor system
according to aspects of the present invention;
FIG. 4 is a top perspective view of the sole and the sensor system of FIG. 3,
with a
foot contacting member of the shoe removed and an electronic module removed;
FIG. 5 is a top perspective view of the sole of FIG. 3, with the foot
contacting
member of the shoe removed and without the sensor system;
FIG. 6 is a schematic diagram of one embodiment of an electronic module
capable of
use with a sensor system, in communication with an external electronic device;
FIG. 7 is a top view of an insert of the sensor system of FIG. 3, adapted to
be
positioned within the sole structure of an article of footwear for a user's
right foot;
FIG. 8 is a top perspective view of the insert of FIG. 7;
FIG. 9 is a top view of the sensor system of FIG. 3, including the insert of
FIG. 7;
FIG. 10 is a top perspective view of the sensor system of FIG. 9;
FIG. 11 is a magnified top view of a portion of the sensor system of FIG. 9;
FIG. 12 is a top view of the sensor system of FIG. 9 and a similar sensor
system
adapted for use in the sole structure of an article of footwear for a user's
left foot;
FIG. 13 is an exploded perspective view of the insert of FIG. 7, showing four
different
layers;
FIG. 14 is a top view of a first layer of the insert of FIG. 13;
FIG. 15 is a magnified top view of a portion of the first layer of FIG. 14;
FIG. 16 is a top view of a second layer of the insert of FIG. 13;
FIG. 17 is a magnified top view of a portion of the second layer of FIG. 16;
FIG. 18 is a top view of a spacer layer of the insert of FIG. 13;
FIG. 19 is a top view of a bottom layer of the insert of FIG. 13;
FIG. 20 is a schematic circuit diagram illustrating one embodiment of a
circuit formed
by the components of the sensor system of FIG. 9;
FIG. 21 is magnified cross-sectional view schematically illustrating the area
indicated
by lines 21-21 in FIG. 11;
FIG. 22A is a bottom view of the sensor system of FIG. 9;
FIG. 22B is a bottom view of the sensor system as illustrated in FIG. 22A,
having
filters connected over vents in the sensor system;
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FIG. 22C is a top view of a spacer layer of another embodiment of an insert
for a
sensor system according to aspects of the present invention, with broken lines
showing
positions of sensors;
FIG. 22D is a bottom view of an insert for a sensor system incorporating the
spacer
layer of FIG. 22C, with broken lines showing positions of filters connected to
insert;
FIG. 23 is a schematic diagram of the electronic module of FIG. 6, in
communication
with an external gaming device;
FIG. 24 is a schematic diagram of a pair of shoes, each containing a sensor
system, in
a mesh communication mode with an external device;
FIG. 25 is a schematic diagram of a pair of shoes, each containing a sensor
system, in
a "daisy chain" communication mode with an external device;
FIG. 26 is a schematic diagram of a pair of shoes, each containing a sensor
system, in
an independent communication mode with an external device;
FIG. 27 is a plot showing pressure vs. resistance for one embodiment of a
sensor
according to aspects of the present invention;
FIG. 28 is a schematic cross-sectional view of a portion of the sole and
sensor system
of FIG. 4;
FIG. 29 is a schematic cross-sectional view of a portion of another embodiment
of a
sole and sensor system according to aspects of the present invention;
FIG. 30 is a top view of the sole of FIG. 3 with the foot contacting member in
operational position;
FIG. 31 is a cross-sectional view schematically depicting the view taken along
lines
31-31 of FIG. 10;
FIG. 32 is a cross-sectional view schematically depicting the view taken along
lines
32-32 of FIG. 10;
FIG. 33 is an exploded perspective view of another embodiment of a sensor
system
according to aspects of the present invention;
FIG 34 is an exploded perspective view of another embodiment of a sensor
system
according to aspects of the present invention;
FIGS. 35A and 35B are schematic cross-sectional views of a sensor of the
sensor
system of FIG. 7;
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FIG. 36 is a top perspective view of a sole of a shoe (having a shoe upper
removed
and a foot contacting member folded aside) incorporating another embodiment of
a sensor
system according to aspects of the present invention;
FIG. 37 is a top perspective view of the sole of FIG. 36, with the foot
contacting
member of the shoe removed and without the sensor system;
FIG. 38 is a top perspective view of the sole and the sensor system of FIG.
36, with a
foot contacting member of the shoe removed and an electronic module removed;
FIG. 39 is a top view of an insert of the sensor system of FIG. 36, adapted to
be
positioned within the sole structure of an article of footwear for a user's
right foot;
FIG. 40 is a top view of a first layer of the insert of FIG. 39;
FIG. 41 is a top view of a second layer of the insert of FIG. 39;
FIG. 42 is a top view of a spacer layer of the insert of FIG. 39;
FIG. 43 is a top view of a bottom layer of the insert of FIG. 39;
FIG. 44 is an exploded perspective view of the insert of FIG. 39, showing four
different layers;
FIG. 45 is a top perspective view of a sole of a shoe (having a shoe upper
removed
and a foot contacting member folded aside) incorporating another embodiment of
a sensor
system according to aspects of the present invention;
FIG. 46 is a top perspective view of the sole of FIG. 45, with the foot
contacting
member of the shoe removed and without the sensor system;
FIG. 47 is a top perspective view of the sole and the sensor system of FIG.
45, with a
foot contacting member of the shoe removed and an electronic module removed;
FIG. 48 is a top view of another embodiment of an insert of the sensor system
adapted
to be positioned within the sole structure of an article of footwear for a
user's right foot,
according to aspects of the present invention;
FIG. 49 is a top view of a first layer of the insert of FIG. 48;
FIG. 50 is a top view of a spacer layer of the insert of FIG. 48;
FIG. 51 is a top view of a second layer of the insert of FIG. 48;
FIG. 52 is a top view of another embodiment of an insert of a sensor system
according
to aspects of the present invention;
FIG. 53 is a top view of a first layer of the insert of FIG. 52;
FIG. 54 is a top view of a spacer layer of the insert of FIG. 52;
FIG. 55 is a top view of a second layer of the insert of FIG. 52;
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FIG. 56 is a cross-sectional view taken along lines 56-56 in FIG. 52;
FIG. 57 is a schematic cross-sectional view illustrating one embodiment of a
method
and equipment for forming a well in a sole structure of an article of
footwear, according to
aspects of the present invention;
FIG. 58 is a schematic cross-sectional view illustrating the sole structure of
the article
of footwear of FIG. 57 with an insert member of a sensor system and a foot
contacting
member connected thereto;
FIG. 59 is a schematic cross-sectional view illustrating another embodiment of
a
sensor system positioned within a sole structure of an article of footwear,
according to
aspects of the present invention;
FIG. 59A is a schematic cross-sectional view illustrating another embodiment
of a
sensor system positioned within a sole structure of an article of footwear,
according to
aspects of the present invention;
FIG. 60 is a perspective view of one embodiment of a foot contacting member
configured for use with a sensor system according to aspects of the present
invention;
FIG. 61 is a perspective view of another embodiment of a sensor system
according to
aspects of the present invention;
FIGS. 62-64 illustrate a plan view and perspective views of the port in the
insert
member according to aspects of the invention;
FIGS. 65-67 illustrate components of a housing of the port;
FIGS. 68-71 illustrate views of an interface assembly used in the port;
FIGS. 72-73 illustrate views of the interface assembly operably connected to
the
insert member;
FIG. 74 is a partial enlarged plan view of the port connected to the insert
member and
having a cover member removed;
FIGS. 75-76 are side elevation views of the port attached to the insert
member;
FIGS. 77-78 are additional views of the module according to aspects of the
invention;
FIGS. 79-80 are perspective views of contacts and a module carrier according
to
aspects of the invention;
FIGS. 81-83 are perspective view of components of the module;
FIG. 84 is a partial cross-sectional view showing over-molding of contacts of
an
interface of the module;
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FIGS. 85-86 are plan views of the module showing a light assembly according to
aspects of the invention;
FIGS. 87-90 are internal views of the module showing components of the light
assembly; and
FIGS. 91-94 are views of a PCB and a ground plane extender associated with the
module according to aspects of the invention.
DETAILED DESCRIPTION
[0016] While this invention is susceptible of embodiment in many different
forms, there
are shown in the drawings, and will herein be described in detail, preferred
embodiments of
the invention with the understanding that the present disclosure is to be
considered as an
exemplification of the principles of the invention and is not intended to
limit the broad
aspects of the invention to the embodiments illustrated and described.
[0017] Footwear, such as a shoe, is shown as an example in FIGS. 1-2 and
generally
designated with the reference numeral 100. The footwear 100 can take many
different forms,
including, for example, various types of athletic footwear. In one exemplary
embodiment,
the shoe 100 generally includes a force and/or pressure sensor system 12
operably connected
to a universal communication port 14. As described in greater detail below,
the sensor
system 12 collects performance data relating to a wearer of the shoe 100.
Through
connection to the universal communication port 14, multiple different users
can access the
performance data for a variety of different uses as described in greater
detail below.
[0018] An article of footwear 100 is depicted in FIGS. 1-2 as including an
upper 120 and
a sole structure 130. For purposes of reference in the following description,
footwear 100
may be divided into three general regions: a forefoot region 111, a midfoot
region 112, and a
heel region 113, as illustrated in Figure 1. Regions 111-113 are not intended
to demarcate
precise areas of footwear 100. Rather, regions 111-113 are intended to
represent general
areas of footwear 100 that provide a frame of reference during the following
discussion.
Although regions 111-113 apply generally to footwear 100, references to
regions 111-113
also may apply specifically to upper 120, sole structure 130, or individual
components
included within and/or formed as part of either upper 120 or sole structure
130.
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[0019] As further shown in FIGS. 1 and 2, the upper 120 is secured to sole
structure 130
and defines a void or chamber for receiving a foot. For purposes of reference,
upper 120
includes a lateral side 121, an opposite medial side 122, and a vamp or instep
area 123.
Lateral side 121 is positioned to extend along a lateral side of the foot
(i.e., the outside) and
generally passes through each of regions 111-113. Similarly, medial side 122
is positioned to
extend along an opposite medial side of the foot (i.e., the inside) and
generally passes through
each of regions 111-113. Vamp area 123 is positioned between lateral side 121
and medial
side 122 to correspond with an upper surface or instep area of the foot. Vamp
area 123, in
this illustrated example, includes a throat 124 having a lace 125 or other
desired closure
mechanism that is utilized in a conventional manner to modify the dimensions
of upper 120
relative the foot, thereby adjusting the fit of footwear 100. Upper 120 also
includes an ankle
opening 126 that provides the foot with access to the void within upper 120. A
variety of
materials may be used for constructing upper 120, including materials that are
conventionally
utilized in footwear uppers. Accordingly, upper 120 may be formed from one or
more
portions of leather, synthetic leather, natural or synthetic textiles, polymer
sheets, polymer
foams, mesh textiles, felts, non-woven polymers, or rubber materials, for
example. The
upper 120 may be formed from one or more of these materials wherein the
materials or
portions thereof are stitched or adhesively bonded together, e.g., in manners
that are
conventionally known and used in the art.
[0020] Upper 120 may also include a heel element (not shown) and a toe
element (not
shown). The heel element, when present, may extend upward and along the
interior surface
of upper 120 in the heel region 113 to enhance the comfort of footwear 100.
The toe element,
when present, may be located in forefoot region 111 and on an exterior surface
of upper 120
to provide wear-resistance, protect the wearer's toes, and assist with
positioning of the foot.
In some embodiments, one or both of the heel element and the toe element may
be absent, or
the heel element may be positioned on an exterior surface of the upper 120,
for example.
Although the configuration of upper 120 discussed above is suitable for
footwear 100, upper
120 may exhibit the configuration of any desired conventional or non-
conventional upper
structure without departing from this invention.
[0021] As shown in FIG. 3, the sole structure 130 is secured to a lower
surface of upper
120 and may have a generally conventional shape. The sole structure 130 may
have a
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multipiece structure, e.g., one that includes a midsole 131, an outsole 132,
and a foot
contacting member 133. The foot contacting member 133 is typically a thin,
compressible
member that may be located within the void in upper 120 and adjacent to a
lower surface of
the foot (or between the upper 120 and midsole 131) to enhance the comfort of
footwear 100.
In various embodiments, the foot contacting member 133 may be a sockliner, a
strobel, an
insole member, a bootie element, a sock, etc. In the embodiment shown in FIGS.
3-5, the
foot contacting member 133 is an insole member or a sockliner. The term "foot
contacting
member," as used herein does not necessarily imply direct contact with the
user's foot, as
another element may interfere with direct contact. Rather, the foot contacting
member forms
a portion of the inner surface of the foot-receiving chamber of an article of
footwear. For
example, the user may be wearing a sock that interferes with direct contact.
As another
example, the sensor system 12 may be incorporated into an article of footwear
that is
designed to slip over a shoe or other article of footwear, such as an external
bootie element or
shoe cover. In such an article, the upper portion of the sole structure may be
considered a
foot contacting member, even though it does not directly contact the foot of
the user. In some
arrangements, an insole or sockliner may be absent, and in other embodiments,
the footwear
100 may have a foot contacting member positioned on top of an insole or
sockliner.
[0022] Midsole member 131 may be or include an impact attenuating member,
and may
include multiple members or elements in some embodiments. For example, the
midsole
member 131 may be formed of polymer foam material, such as polyurethane,
ethylvinylacetate, or other materials (such as phylon, phylite, etc.) that
compress to attenuate
ground or other contact surface reaction forces during walking, running,
jumping, or other
activities. In some example structures according to this invention, the
polymer foam material
may encapsulate or include various elements, such as a fluid-filled bladder or
moderator, that
enhance the comfort, motion-control, stability, and/or ground or other contact
surface
reaction force attenuation properties of footwear 100. In still other example
structures, the
midsole 131 may include additional elements that compress to attenuate ground
or other
contact surface reaction forces. For instance, the midsole 131 may include
column type
elements to aid in cushioning and absorption of forces.
[0023] Outsole 132 is secured to a lower surface of midsole 131 in this
illustrated
example footwear structure 100 and is formed of a wear-resistant material,
such as rubber or
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a flexible synthetic material, such as polyurethane, that contacts the ground
or other surface
during ambulatory or other activities. The material forming outsole 132 may be
manufactured of suitable materials and/or textured to impart enhanced traction
and slip
resistance. The outsole 132 shown in FIGS. 1 and 2 is shown to include a
plurality of
incisions or sipes 136 in either or both sides of the outsole 132, although
many other types of
outsoles 132 with various types of treads, contours, and other structures may
be used in
connection with the present invention. It is understood that embodiments of
the present
invention may be used in connection with other types and configurations of
shoes, as well as
other types of footwear and sole structures.
[0024] FIGS. 1-5 illustrate exemplary embodiments of the footwear 100
incorporating a
sensor system 12 in accordance with the present invention, and FIGS. 3-22B
illustrate
exemplary embodiments of the sensor system 12. The sensor system 12 includes
an insert
member 37 having a force and/or pressure sensor assembly 13 connected thereto.
The insert
member 37 is configured to be positioned in contact with the sole structure
130 of the
footwear 100, and in one embodiment, the insert member 37 is configured to be
positioned
underneath the foot contacting member 133 and over the top of the midsole
member 131 and
in general confronting relation. The sensor assembly 13 includes a plurality
of sensors 16,
and a communication or output port 14 in communication with the sensor
assembly 13 (e.g.,
electrically connected via conductors). The port 14 is configured for
communicating data
received from the sensors 16, such as to an electronic module (also referred
to as an
electronic control unit) 22 as described below. The port 14 and/or the module
22 may be
configured to communicate with an external device, as also described below. In
the
embodiment illustrated in FIGS. 3-5, the system 12 has four sensors 16: a
first sensor 16a at
the big toe (first phalange or hallux) area of the shoe, two sensors 16b-c at
the forefoot area
of the shoe, including a second sensor 16b at the first metatarsal head region
and a third
sensor 16c at the fifth metatarsal head region, and a fourth sensor 16d at the
heel. These
areas of the foot typically experience the greatest degree of pressure during
movement. Each
sensor 16 is configured for detecting a pressure exerted by a user's foot on
the sensor 16.
The sensors communicate with the port 14 through sensor leads 18, which may be
wire leads
and/or another electrical conductor or suitable communication medium. For
example, in the
embodiment of FIGS. 3-5, the sensor leads 18 may be an electrically conductive
medium that
is printed on the insert member 37, such as a silver-based ink or other
metallic ink, such as an
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ink based on copper and/or tin. The leads 18 may alternately be provided as
thin wires in one
embodiment. In other embodiments, the leads 18 may be connected to the foot
contacting
member 133, the midsole member 131, or another member of the sole structure
130.
[0025] Other embodiments of the sensor system 12 may contain a different
number or
configuration of sensors 16, and generally include at least one sensor 16. For
example, in one
embodiment, the system 12 includes a much larger number of sensors, and in
another
embodiment, the system 12 includes two sensors, one in the heel and one in the
forefoot of
the shoe 100. In addition, the sensors 16 may communicate with the port 14 in
a different
manner, including any known type of wired or wireless communication, including
Bluetooth
and near-field communication. A pair of shoes may be provided with sensor
systems 12 in
each shoe of the pair, and it is understood that the paired sensor systems may
operate
synergistically or may operate independently of each other, and that the
sensor systems in
each shoe may or may not communicate with each other. The communication of the
sensor
systems 12 is described in greater detail below. It is understood that the
sensor system 12
may be provided with computer programs/algorithms to control collection and
storage of data
(e.g., pressure data from interaction of a user's foot with the ground or
other contact surface),
and that these programs/algorithms may be stored in and/or executed by the
sensors 16, the
module 22, and/or the external device 110.
[0026] The sensor system 12 can be positioned in several configurations in
the sole 130
of the shoe 100. In the examples shown in FIGS. 3-5, the port 14, the sensors
16, and the
leads 18 can be positioned between the midsole 131 and the foot contacting
member 133,
such as by positioning the insert member 37 between the midsole 131 and the
foot contacting
member 133. The insert member 37 may be connected to one or both of the
midsole and the
foot contacting member 133 in one embodiment. A cavity or well 135 can be
located in the
midsole 131 (FIG. 5) and/or in the foot contacting member 133 for receiving
the electronic
module 22, as described below, and the port 14 may be accessible from within
the well 135 in
one embodiment. The well 135 may further contain a housing 24 for the module
22, and the
housing 24 may be configured for connection to the port 14, such as by
providing physical
space for the port 14 and/or by providing hardware for interconnection between
the port 14
and the module 22. In the embodiment shown in FIG. 5, the well 135 is formed
by a cavity
in the upper major surface of the midsole 131. As shown in FIG. 5, the sole
structure 130
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may include a compressible sole member 138 that has a hole formed therein to
receive the
housing 24, which provides access to the well 135 and/or may be considered a
portion of the
well 135. The insert 37 can be placed on top of the compressible sole member
138 to place
the housing 24 in the well 135. The compressible sole member 138 may confront
the midsole
131 in one embodiment, and may be in direct contact with the midsole 131. It
is understood
that the compressible sole member 138 may confront the midsole 131 with one or
more
additional structures positioned between the compressible sole member 138 and
the midsole
131, such as a strobel member. In the embodiment of FIGS. 3-5, the
compressible sole
member 138 is in the form of a foam member 138 (e.g. an EVA member) located
between the
foot contacting member 133 and the midsole 131, which may be considered a
lower
insole/sockliner in this embodiment. The foam member 138 may be bonded to a
strobel
133A (FIG. 58) of the midsole 131 in one embodiment, such as by use of an
adhesive, and
may cover any stitching on the strobel, which can prevent abrasion of the
insert 37 by the
stitching. This configuration is shown schematically in FIG. 58. In the
embodiment shown
in FIGS. 3-5, the housing 24 has a plurality of walls, including side walls 25
and a base wall
26, and also includes a flange or lip 28 that extends outward from the tops of
the side walls
25 and is configured for connection to the insert 37. In one embodiment, the
flange 28 is a
separate member that connects to a tub 29 to form the housing 24, via pegs 28A
that connect
through holes 28B in the insert 37 located at the front end of the hole 27.
The pegs 28A may
be connected via ultrasonic welding or other technique, and may be received in
receivers in
one embodiment. In an alternate embodiment, an article of footwear 100 may be
manufactured with the tub 29 formed in the sole structure 130, and the flange
28 may be later
connected, such as by a snap connection, optionally after other portions of
the port have also
been assembled. The housing 24 may include retaining structure to retain the
module 22
within the housing 24, and such retaining structure may be complementary with
retaining
structure on the module 22, such as a tab/flange and slot arrangement,
complementary tabs,
locking members, friction-fit members, etc. The housing 24 also includes a
finger recess 29A
located in the flange 28 and/or the tub 29, which provides room for the user's
finger to
engage the module 22 to remove the module 22 from the housing 24. The flange
28
provides a wide base engaging the top of the insert 37, which spreads out the
forces exerted
on the insert 37 and/or on the foot contacting member 133 by the flange 28,
which creates
less likelihood of severe deflection and/or damage of such components. The
rounded corners
on the flange 28 also assists in avoiding damage to the insert 37 and/or the
foot contacting
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member 133. It is understood that the flange 28 may have a different shape
and/or contour in
other embodiments, and may provide similar functionality with different shapes
and/or
contours.
[0027] The foot contacting member 133 is configured to be placed on top of
the foam
member 138 to cover the insert 37, and may contain an indent 134 in its lower
major surface
to provide space for the housing 24, as shown in FIG. 3. The foot contacting
member 133
may be adhered to the foam member 138, and in one embodiment, may be adhered
only in
the forefoot region to permit the foot contacting member 133 to be pulled up
to access the
module 22, as shown in FIG. 3. Additionally, the foot contacting member 133
may include a
tacky or high-friction material (not shown) located on at least a portion of
the underside to
resist slippage against the insert 37 and/or the foam member 138, such as a
silicone material.
For example, in an embodiment where the foot contacting member 133 is adhered
in the
forefoot region and free in the heel region (e.g. FIG. 3), the foot contacting
member 133 may
have the tacky material located on the heel region. The tacky material may
also provide
enhanced sealing to resist penetration of dirt into the sensor system. In
another embodiment,
as shown in FIG. 60, the foot contacting member 133 may include a door or
hatch 137
configured to be located over the port 14 and sized to permit insertion and/or
removal of the
module 22 through the foot contacting member 133. The embodiment of the foot
contacting
member 133 shown in FIG. 60 may be usable in place of the foot contacting
member 133 in
FIGS. 3, 36, or 45, to provide access to the port 14 and the module 22. In the
embodiment
shown in FIG. 60, the door 137 has a hinge 137A formed by material attachment
along one
edge of the door 137, allowing the door 137 to be opened and closed by
swinging.
Additionally, the door 137 is formed of the same material as the foot
contacting member 133
in this embodiment, so that no significant loss of cushioning is lost by
inclusion of the door
137. Further, the door 137 may have a tab 137B or other structure to aid in
gripping and
manipulation of the door 137 by the user. In one embodiment, the sensor system
12 may be
positioned on the underside of the foot contacting member 133, and the door
137 may
provide access to the port 14 in such an embodiment (not shown). In another
embodiment,
the door 137 may have a hinge on another edge, or may open in a different
manner, such as
by removal, sliding, etc. In one embodiment, the foot contacting member 133
may also have
graphic indicia 92 thereon, as described below.
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[0028] In one embodiment, as shown in FIGS. 3-5 and 7, the foam member 138
may also
include a recess 139 having the same peripheral shape as the insert 37 to
receive the insert 37
therein, and the bottom layer 69 (FIG. 13) of the insert member 37 may include
adhesive
backing to retain the insert 37 within the recess 139. In one embodiment, a
relatively strong
adhesive, such as a quick bonding acrylic adhesive, may be utilized for this
purpose. The
insert 37 has a hole or space 27 for receiving and providing room for the
housing 24, and the
foam member 138 in this embodiment may also allow the housing 24 to pass
completely
through into and/or through at least a portion of the strobel and/or the
midsole 131. In the
embodiment shown in FIGS. 3-5, the foot contacting member 133 may have a
thickness that
is reduced relative to a typical foot contacting member 133 (e.g. sockliner),
with the thickness
of the foam member 138 being substantially equal to the reduction in thickness
of the foot
contacting member 133, to provide equivalent cushioning. In one embodiment,
the foot
contacting member 133 may be a sockliner with a thickness of about 2-3mm, and
the foam
member 138 may have a thickness of about 2 mm, with the recess 139 having a
depth of
about lmm. The foam member 138 may be adhesively connected to the insert
member 37
prior to connecting the foam member 138 to the article of footwear 100 in one
embodiment.
This configuration permits the adhesive between the foam member 138 and the
insert 37 to
set in a flat condition before attaching the foam member to the strobel or
other portion of the
footwear 100, which is typically bends or curves the foam member 138 and may
otherwise
cause delamination. The foam member 138 with the insert 37 adhesively attached
may be
provided in this configuration as a single product for insertion into an
article of footwear 100
in one embodiment. The positioning of the port 14 in FIGS. 3-5 not only
presents minimal
contact, irritation, or other interference with the user's foot, but also
provides easy
accessibility by simply lifting the foot contacting member 133.
[0029] In the embodiment of FIGS. 3-5, the housing 24 extends completely
through the
insert 37 and the foam member 138, and the well 135 also extends completely
through the
strobel 133A and partially into the midsole 131 of the footwear 100 to receive
the housing 24,
as illustrated schematically in FIG. 58. In another embodiment, the well 135
may be
differently configured, and may be positioned completely underneath the
strobel 133A in one
embodiment, with a window through the strobel 133A to permit access to the
module 22 in
the well 135. The well 135 may be formed using a variety of techniques,
including cutting or
removing material from the strobel 133A and/or the midsole 131, forming the
strobel 133A
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and/or the midsole 131 with the well contained therein, or other techniques or
combinations
of such techniques. In one embodiment, a hot knife 109 is used to cut through
the strobel
133A and into the midsole 131 to remove a piece 135A of material to form the
well 135, as
illustrated schematically in FIG. 57. In this embodiment, the hot knife 109
includes a wall
109A extending around the periphery of the hot knife 109 to define a cavity
109B that
receives the piece 135A to be removed, as well as prongs 109C that extend down
through the
middle of the piece 135A. The wall 109A cuts down into the strobel 133A and
the midsole
131 to cut the outer boundaries of the piece 135A to be removed. The prongs
109C both
weaken the bottom side of the piece 135A to facilitate removal and also assist
in retaining the
piece 135A within the cavity 109B during removal, so the piece 135A can be
removed by
simply lifting the hot knife 109 away from the sole structure 130. In one
embodiment, the
hot knife 109 may be heated to a temperature of between 250-260 C. In other
embodiments,
a hot knife 109 (which may be differently configured) may be utilized to form
a differently
shaped and/or configured well 135 in the sole structure 130. FIG. 58
schematically illustrates
the insert 37 connected to the sole structure 130 and the housing 24 received
in the well 135
after formation. As shown in FIG. 58, the housing 24 fits closely with the
walls of the well
135, which can be advantageous, as gaps between the housing 24 and the well
135 may be
sources of material failure. The process of removing the piece 135 may be
automated using
appropriate computer control equipment.
[0030] The well 135 may be located elsewhere in the sole structure 130 in
further
embodiments. For example, the well 135 may be located in the upper major
surface of the
foot contacting member 133 and the insert 37 can be placed on top of the foot
contacting
member 133. As another example, the well 135 may be located in the lower major
surface of
the foot contacting member 133, with the insert 37 located between the foot
contacting
member 133 and the midsole 131. As a further example, the well 135 may be
located in the
outsole 132 and may be accessible from outside the shoe 100, such as through
an opening in
the side, bottom, or heel of the sole 130. In the configurations illustrated
in FIGS. 3-5, the
port 14 is easily accessible for connection or disconnection of an electronic
module 22, as
described below. In the embodiment illustrated in FIG. 59, the foot contacting
member 133
has the insert 37 connected to the bottom surface, and the port 14 and the
well 135 are formed
in the sole structure 130, such as in the same configuration described above
and shown in
FIG. 58. The interface 20 is positioned on the side of the housing 24 as
similarly shown with
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respect to other embodiments, although it is understood that the interface 20
could be
positioned elsewhere, such as for engagement through the top of the module 22.
The module
22 may be altered to accommodate such a change. In this embodiment, the foot
contacting
member 133 may be provided with an opening for accessing the module 22 (such
as in FIG.
60) or may be able to be pulled upward to access the module 22, as shown in
FIG. 3. In the
embodiment illustrated in FIG. 59A, the insert 37 is positioned below both the
foot contacting
member 133 and the strobel 133A, and in contact with the midsole member 131.
In this
embodiment, the strobel 133A and/or the foot contacting member 133 may be
provided with
openings for accessing the module 22 and/or may be able to be pulled upward to
access the
module 22, as shown in FIG. 3.
[0031] In other embodiments, the sensor system 12 can be positioned
differently. For
example, in one embodiment, the insert 37 can be positioned within the outsole
132, midsole
131, or foot contacting member 133. In one exemplary embodiment, insert 37 may
be
positioned within a foot contacting member 133 positioned above an insole
member, such as
a sock, sockliner, interior footwear bootie, or other similar article, or may
be positioned
between the foot contacting member 133 and the insole member. Still other
configurations
are possible, and some examples of other configurations are described below.
As discussed,
it is understood that the sensor system 12 may be included in each shoe in a
pair.
[0032] The insert member 37 in the embodiment illustrated in FIGS. 3-22B is
formed of
multiple layers, including at least a first layer 66 and a second layer 68.
The first and second
layers 66, 68 may be formed of a flexible film material, such as a Mylar0 or
other PET
(polyethylene terephthalate) film, or another polymer film, such as polyamide.
In one
embodiment, the first and second layers 66, 68 may each be PET films having
thicknesses of
0.05-0.2mm, such as a thickness of 125 m. Additionally, in one embodiment,
each of the
first and second layers 66, 68 has a minimum bend radius of equal to or less
than 2mm. The
insert 37 may further include a spacer layer 67 positioned between the first
and second layers
66, 68 and/or a bottom layer 69 positioned on the bottom of the insert 37
below the second
layer 68, which are included in the embodiment illustrated in FIGS. 3-22B. The
layers 66,
67, 68, 69 of the insert 37 are stacked on top of each other and in
confronting relation to each
other, and in one embodiment, the layers 66, 67, 68, 69 all have similar or
identical peripheral
shapes and are superimposed on one another (FIG. 13). In one embodiment, the
spacer layer
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67 and the bottom layer 69 may each have a thickness of 89-111 m, such as a
thickness of
100 m. The entire thickness of the insert member 37 may be about 450 m in one
embodiment, or about 428-472 m in another embodiment, and about 278-622 m in a
further
embodiment. The insert 37 may also include additional adhesive that is 100-225
m thick,
and may further include one or more selective reinforcement layers, such as
additional PET
layers, in other embodiments. Additionally, in one embodiment, the entire four-
layer insert
as described above has a minimum bend radius of equal to or less than 5mm. It
is understood
that the orientations of the first and second layers 66, 68 may be reversed in
another
embodiment, such as by placing the second layer 68 as the top layer and the
first layer 66
below the second layer 68. In the embodiment of FIGS. 3-22B, the first and
second layers
66, 68 have various circuitry and other components printed thereon, including
the sensors 16,
the leads 18, resistors 53, 54, a pathway 50, dielectric patches 80, and other
components,
which are described in greater detail below. The components are printed on the
underside of
the first layer 66 and on the upper side of the second layer 68 in the
embodiment of FIGS. 3-
22B, however in other embodiments, at least some components may be printed on
the
opposite sides of the first and second layers 66, 68. It is understood that
components located
on the first layer 66 and/or the second layer 68 may be moved/transposed to
the other layer
66, 68. In one embodiment, the components may be printed on the layers 66, 68
in a manner
so as to limit the total number of printer passes required, and in one
embodiment, all the
components on an individual layer 66, 68 may be printed in a single pass.
[0033] The layers 66, 67, 68, 69 can be connected together by an adhesive
or other
bonding material in one embodiment. The spacer layer 67 may contain adhesive
on one or
both surfaces in one embodiment to connect to the first and second layers 66,
68. The bottom
layer 69 may likewise have adhesive on one or both surfaces, to connect to the
second layer
68 as well as to the article of footwear 100. The first or second layers 66,
68 may
additionally or alternately have adhesive surfaces for this purpose. A variety
of other
techniques can be used for connecting the layers 66, 67, 68, 69 in other
embodiments, such as
heat sealing, spot welding, or other known techniques.
[0034] The insert 37, the foot contacting member 133, and/or other
components of the
sensor system 12 and the footwear 100 may also include a graphic design or
other indicia (not
shown) thereon. The graphic design may be provided on one or more graphic
layers (not
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shown) that may be connected to the insert 37, such as by overlaying the
graphic layer on top
of the first layer 66. The graphic design may correspond to the sensor
assembly 13, leads 18
and the various other components supported by the layer. For example, in the
embodiment of
FIG. 60, the foot contacting member 133 has graphical indicia 92 that forms a
graphical
depiction of the insert 37 of the sensor system 12 that is positioned below
the foot contacting
member 133. Other graphical designs may be used in other embodiments,
including
informative, stylistic, and other such designs.
[0035] The insert 37 illustrated in FIGS. 3-22B has a configuration that
may utilize less
material than other insert configurations and may provide greater resistance
to tearing at
common stress points. In this embodiment, the insert 37 has several portions
of material cut
out of areas of the insert 37 that may be superfluous, such as in the lateral
forefoot area or the
lateral and medial heel areas. The insert 37 in this configuration has a
midfoot portion 37A
configured to be engaged by the midfoot region of the user's foot and a
forefoot portion 37B
configured to be engaged by the forefoot (i.e. metatarsal) region of the
user's foot, with a heel
portion 37C extending rearwardly from the midfoot portion 37A and a first
phalange portion
37D extending forwardly from the forefoot portion, configured to be engaged by
the heel
region and the first phalange region of the user's foot, respectively. FIGS.
4, 8, 10, and 22A
illustrate these features in greater detail. It is understood that, depending
on the shape of the
user's foot, the first phalange portion 37D may engage only the first phalange
region of the
user's foot. In this embodiment, the width of the forefoot portion 37B is
greater than the
width of the midfoot portion 37A, and both the midfoot and forefoot portions
37A-B have
greater width than the first phalange portion 37D and the heel portion 37C,
such that the first
phalange portion 37D and the heel portion 37C are configured as peninsulas
that extend
forward or rearward, respectively, from a base at the wider midfoot and
forefoot portions
37A-B to a free end in elongated manners. As referred to herein, the width of
a portion of the
insert 37 is measured in the medial-to-lateral direction, and the length is
measured in the
front-to-rear (toe-to-heel) direction. In the embodiment of FIGS. 3-22B, the
first phalange
portion 37D has one of the sensors 16a located thereon, to be engaged by the
first phalange of
the user, and the heel portion 37C has another one of the sensors 16d thereon,
to be engaged
by the heel of the user. The remaining two sensors 16b, 16c are located on the
forefoot
portion 37B of the insert 37, specifically at the first metatarsal head region
and at the fifth
metatarsal head region, to be engaged by the first and fifth metatarsal head
regions of the
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user's foot, respectively. The midfoot portion 37A contains the hole 27 for
receiving the
housing 24 and module 22, and the hole 27 defines two strips 88 that extend
between and
connect the forefoot portion 37B and the heel portion 37C. In one embodiment,
the strips 88
have minimum widths of 8 mm or widths within a range of 3-5% of the overall
length of the
insert 37. In this usage, the length of the insert 37 is measured from the
forefoot-most end of
the first phalange portion 37D to the heel-most end of the heel portion 37C.
These strips 88
undergo high stresses during use, and this width assists in avoiding failure
during use. In
other embodiments, the strips 88 may be reinforced by additional structure.
For example, in
one embodiment, the strips 88 and/or other portions of the insert 37 may be
reinforced by
fibers or similar structures. As another example, the insert 37 may include an
additional
structural layer over at least a portion of the insert 37 in one embodiment,
such as an
additional structural layer that completely surrounds the housing 24 and
occupies the
entireties of both strips 88 and the junctures between the strips 88 and the
remainder of the
insert 37.
[0036] In the embodiment shown in FIGS. 3-22B, the insert 37 has a
peripheral edge
defining a periphery of the insert 37, and including a medial edge 85
extending along the
medial side of the insert 37 from the back of the heel portion 37C to the
front end of the first
phalange portion 37D, a lateral edge 86 extending from the back of the heel
portion 37C to
the front of the forefoot portion 37B, and a front edge 87 extending from the
lateral edge 86
to the first phalange portion 37D along second, third, fourth, and fifth
metatarsal areas of the
insert 37. The medial edge 85, the lateral edge 86, and the front edge 87 each
have a cut-out
portion in this embodiment, as shown, for example, in FIGS. 8, 10, and 22A.
The cut-out
portion 87A along the front edge 87 is located between the lateral edge 86 and
the first
phalange portion (i.e. peninsula) 37D. The cut-out portions 85A, 86A along the
medial and
lateral edges 85, 86 are located proximate the juncture between the forefoot
portion 37B and
the midfoot portion 37A, and the width W1 of the insert 37 (defined between
the medial and
lateral edges 85, 86) in the midfoot portion 37A and the width W2 in the
forefoot portion 37B
are greater than the width W3 of the insert measured between the first and
second cut-outs
85A, 86A. This configuration creates a narrowed neck 89 between the midfoot
portion 37A
and the forefoot portion 37B that is narrower than either the midfoot portion
37A or the
forefoot portion 37B. The widths W1 , W2 of the midfoot portion 37A and
forefoot portion
37B are also greater than the width W4 measured at the heel portion 37C, and
the forefoot
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portion 37B has the greatest relative width W2. The heel portion 37C in this
embodiment
includes a widened tail portion 37E that is wider than the more forward
portions of the heel
portion 37C, such that the heel portion 37C increases in width from the
midfoot portion 37A
toward the heel end of the insert member 37.
[0037] The cut out portions 85A, 86A, 87A each extend inwardly into the
body of the
insert 37 and generally have a concave and/or indented shape. In the
embodiment illustrated
in FIGS. 3-22B, each of the cut out portions 85A, 86A, 87A has a smooth and
concave
inwardly curved (curvilinear) shape, which resists ripping, tearing, or
propagation of cracks
in the insert 37. In this embodiment, each of the cut out portions 85A, 86A,
87A is at least
partially defined by a concave curvilinear edge defining an arc of at least
120 . Additionally,
in one embodiment, at least one of the cut out portions 85A, 86A, 87A is at
least partially
defined by a concave curvilinear edge defining an arc of at least 180 . As
seen, for example,
in FIGS. 8, 10, and 22A, at least the medial and lateral cut out portions 85A,
86A are each at
least partially defined by a concave curvilinear edge defining an arc of at
least 180 .
Additionally, each of the cut out portions 85A, 86A, 87A in this embodiment is
bounded on
both sides by smoothly curved edges located on the outer periphery of the
insert, at the
medial, lateral, and front edges 85, 86, 87. One or both of the smoothly
curved edges
bounding each of the cut out portions 85A, 86A, 87A in this embodiment defines
an arc of at
least 90 . The use of the cut out portions 85A, 86A, 87A in these locations
and with these
configurations can increase the durability and longevity of the insert 37, for
example, by
resisting ripping, tearing, or propagation of cracks in the insert 37 as
described above. In this
embodiment, the cut out portions 85A, 86A, 87A are positioned in high stress
areas, where
this damage resistance is most beneficial. The insert 37 configured as shown
in FIGS. 3-22B
may have sufficient fatigue resistance to withstand stresses of up to 20 MPa
over at least
500,000 cycles.
[0038] In further embodiments, the insert 37 may have different cut out
portions and/or
may have cut out portions in the same locations but with different shapes. For
example, the
insert 37' shown in FIGS. 22C-D has cut out portions 85A, 86A, 87A in similar
locations as
compared to the insert 37 of FIGS. 3-22B, with the cut out portions 85A, 86A,
87A having
slightly different peripheral shapes. In this embodiment, the medial cut out
portion 85A
defines a smaller arc as compared to the medial cut out portion 85A of the
insert 37 of FIGS.
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3-22B. The front cut out portion 87A of this embodiment defines a shape that
is less
symmetrical and evenly curved as compared to the front cut out portion 87A of
the insert 37
of FIGS. 3-22B.
[0039] FIGS. 36-47 illustrate additional embodiments of sensor systems 412,
512 with
inserts 437, 537 that have different shapes and configurations than the sensor
system 12 and
the insert 37 described above and shown in FIGS. 3-22B. The sensor systems
412, 512 of
FIGS. 36-47 include many structural and functional features in common with the
sensor
system 12 of FIGS. 3-22B. For example, the sensor systems 412, 512 include
sensors 16 that
are configured and positioned substantially the same and function in a similar
manner as the
sensor system 12 of FIGS. 3-22B. As another example, the sensor systems 412,
512 include
two fixed resistors 53, 54 in parallel and a pathway 50 between the layers 66,
68, similar to
the sensor system 12 of FIGS. 3-22B. These and other such common features may
not be
described again herein for the sake of brevity.
[0040] In the embodiment of FIGS. 36-44, the insert 437 has cut out
portions 85A, 86A,
87A in similar locations as compared to the insert 37 of FIGS. 3-22B, with the
cut out
portions 85A, 86A, 87A having slightly different peripheral shapes. In this
embodiment, the
medial cut out portion 85A defines a smaller arc as compared to the medial cut
out portion
85A of the insert 37 of FIGS. 3-22B. The front cut out portion 87A of this
embodiment is
deeper and defines a larger arc as compared to the front cut out portion 87A
of the insert 37
of FIGS. 3-22B. The lateral cut out portion 86A of this embodiment is
shallower and defines
a smaller arc as compared to the lateral cut out portion 86A of the insert 37
of FIGS. 3-22B.
Additionally, the insert 437 of FIGS. 36-44 has a heel portion 37C with a
substantially
constant width, and has no widened tail portion 37E.
[0041] In the embodiment of FIGS. 45-47, the insert 537 has cut out
portions 85A, 86A,
87A in similar locations as compared to the insert 37 of FIGS. 3-22B, with the
cut out
portions 85A, 86A, 87A having slightly different peripheral shapes. In this
embodiment, the
medial cut out portion 85A defines a smaller arc as compared to the medial cut
out portion
85A of the insert 37 of FIGS. 3-22B. The lateral cut out portion 86A of this
embodiment is
shallower and defines a smaller arc as compared to the lateral cut out portion
86A of the
insert 37 of FIGS. 3-22B. The front edge 87 of the insert 537 of FIGS. 45-48
is angled
steadily from the first phalange portion 37D toward the fifth metatarsal
sensor 16c, and
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defines a substantially straight edge that extends directly into the front cut
out portion 87A.
The resultant front cut out portion 87A defines a smaller arc as compared to
the front cut out
portion 87A of the insert 37 of FIGS. 3-22B. Additionally, the insert 537 of
FIGS. 45-48 has
a heel portion 37C with a substantially constant width, and has no widened
tail portion 37E.
The leads 18 and many other components of the sensor system 512 of FIGS. 45-48
are not
illustrated and/or referenced herein, and it is understood that such
components may be
configured similarly or identically to the corresponding components in the
sensor system 12
of FIGS. 3-22B and/or the sensor system 412 in FIGS. 36-44 (structurally
and/or
functionally).
[0042] It is understood that inserts 37, 37', 437, 537 may have any number
of different
configurations, shapes, and structures, and including a different number
and/or configuration
of sensors 16, and a different insert structure or peripheral shape. For
example, any of the
inserts 37, 37', 437, 537 described herein may include some or all of the
structural features
and the functions associated with such structural features as described above,
such as the cut-
out portions 85A, 86A, 87A and other features of the peripheral shape, while
being
contoured, dimensioned, and configured differently. Additionally, any of the
inserts 37, 37',
437, 537 described herein may include additional or different structural
features that may
provide different shapes and/or functionalities.
[0043] In the embodiment illustrated in FIGS. 3-22B, the sensors 16 are
force and/or
pressure sensors for measuring pressure and/or force on the sole 130. The
sensors 16 have a
resistance that decreases as pressure on the sensor 16 increases, such that
measurement of the
resistance through the port 14 can be performed to detect the pressure on the
sensor 16. The
sensors 16 in the embodiment illustrated in FIGS. 3-22B are elliptical or
obround in shape,
which enables a single sensor size to be utilized in several different shoe
sizes. The sensors
16 in this embodiment each include two contacts 40, 42, including a first
contact 40
positioned on the first layer 66 and a second contact 42 positioned on the
second layer 68. It
is understood that the figures illustrating the first layer 66 herein are top
views, and that the
electronic structures (including the contacts 40, the leads 18, etc.) are
positioned on the
bottom side of the first layer 66 and viewed through a transparent or
translucent first layer 66
unless specifically noted otherwise. The contacts 40, 42 are positioned
opposite each other
and are in superimposed relation to each other, so that pressure on the insert
member 37, such
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as by the user's foot, causes increased engagement between the contacts 40,
42. The
resistance of the sensor 16 decreases as the engagement between the contacts
40, 42
increases, and the module 22 is configured to detect pressure based on changes
in resistance
of the sensors 16. In one embodiment, the contacts 40, 42 may be formed by
conductive
patches that are printed on the first and second layers 66, 68, such as in the
embodiment of
FIGS. 3-22B, and the two contacts 40, 42 may be formed of the same or
different materials.
Additionally, in one embodiment, the leads 18 are formed of a material that
has a higher
conductivity and lower resistivity than the material(s) of the sensor contacts
40, 42. For
example, the patches may be formed of carbon black or another conductive
carbon material.
Further, in one embodiment, the two contacts 40, 42 may be formed of the same
material or
two materials with similar hardnesses, which can reduce abrasion and wear due
to differences
in hardness of the materials in contact with each other. In this embodiment,
the first contacts
40 are printed on the underside of the first layer 66, and the second contacts
42 are printed on
the top side of the second layer 68, to permit engagement between the contacts
40, 42. The
embodiment illustrated in FIGS. 3-22B includes the spacer layer 67, which has
holes 43
positioned at each sensor 16 to permit engagement of the contacts 40, 42
through the spacer
layer 67, while insulating other portions of the first and second layers 66,
68 from each other.
In one embodiment, each hole 43 is aligned with one of the sensors 16 and
permits at least
partial engagement between the contacts 40, 42 of the respective sensor 16. In
the
embodiment illustrated in FIGS. 7-18, the holes 43 are smaller in area than
the sensor
contacts 40, 42, allowing the central portions of the contacts 40, 42 to
engage each other,
while insulating outer portions of the contacts 40, 42 and the distribution
leads 18A from
each other (See, e.g., FIGS. 13 and 35A-B). In another embodiment, the holes
43 may be
sized to permit engagement between the contacts 40, 42 over their entire
surfaces. It is
understood that the size, dimensions, contours, and structure of the sensors
16 and the
contacts 40, 42 may be altered in other embodiments while retaining similar
functionality. It
is also understood that sensors 16 having the same sizes may be utilized in
different sizes of
inserts 37 for different shoe sizes, in which case the dimensions of the
sensors 16 relative to
the overall dimensions of the insert 37 may be different for different insert
37 sizes.
[0044] In other embodiment, the sensor system 12 may have sensors 16 that
are
differently configured than the sensors 16 of the embodiment of FIGS. 3-22B.
For example,
FIGS. 33-34 illustrate additional embodiments of sensor systems 212, 312 that
have sensors
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16 that are configured differently from the sensors 16 in the sensor system 12
of FIGS. 3-
22B. In the embodiments illustrated in FIGS. 33-34, the contacts 40, 42 of the
sensors 16 in
FIGS. 33-34 are configured differently from the contacts 40, 42 of the sensors
16 in the
embodiment of FIGS. 3-22B. Other components and features of the sensor systems
212, 312
are similar or identical to those of the sensor system 12 of FIGS. 3-22B,
including any
variations or alternate embodiments described herein. As another example,
FIGS. 48-51
illustrate an embodiment of a sensor system 712 that includes sensors 16 that
have contacts
740, 742, 744 that are configured differently from the sensors 16 and contacts
40, 42 of the
embodiment of FIGS. 3-22B. In a further example, the sensors 16 may utilize a
different
configuration that does not include carbon-based or similar contacts 40, 42
and/or may not
function as a resistive sensor 16. Examples of such sensors include a
capacitive pressure
sensor or a strain gauge pressure sensor, among other examples.
[0045] As further shown in FIGS. 3-22B, in one embodiment, the insert 37
may include
an internal airflow system 70 configured to allow airflow through the insert
37 during
compression and/or flexing of the insert 37. FIGS. 9, 11, 13, 18, 22A-B, and
28-30 illustrate
the components of the airflow system 70 in greater detail. The airflow system
70 may
include one or more air passages or channels 71 that lead from the sensors 16
to one or more
vents 72, to allow air to flow from the sensor 16 during compression, between
the first and
second layers 66, 68 and outward through the vent(s) 72 to the exterior of the
insert 37. The
airflow system 70 resists excessive pressure buildup during compression of the
sensors 16,
and also permits consistent separation of the contacts 40, 42 of the sensors
16 at various air
pressures and altitudes, leading to more consistent performance. The channels
71 may be
formed between the first and second layers 66, 68. As shown in FIG. 18, the
spacer layer 67
has the channels 71 formed therein, and the air can flow through these
channels 71 between
the first and second layers 66, 68, to the appropriate vent(s) 72. The vents
72 may have
filters 73 covering them in one embodiment, as shown in FIG. 22B. These
filters 73 may be
configured to permit air, moisture, and debris to pass out of the vents 72 and
resist moisture
and debris passage into the vents 72. In another embodiment, the insert 37 may
not contain a
spacer layer, and the channels 71 may be formed by not sealing the layers 66,
68 together in a
specific pattern, such as by application of a non-sealable material. Thus, the
airflow system
70 may be considered to be integral with or directly defined by the layers 66,
68 in such an
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embodiment. In other embodiments, the airflow system 70 may contain a
different number or
configuration of air channels 71, vents 72, and/or other passages.
[0046] In the embodiment illustrated in FIGS. 3-22B, 28, and 30, the
airflow system 70
includes two vents 72 and a plurality of air channels 71 connecting each of
the four sensors
16 to one of the vents 72. The spacer layer 67 includes holes 43 at each
sensor in this
embodiment, and the channels 71 are connected to the holes 43 to permit air to
flow away
from the sensor 16 through the channel 71. Additionally, in this embodiment,
two of the
sensors 16 are connected to each of the vents 72 through channels 71. For
example, as
illustrated in FIGS. 4 and 7-18, the first metatarsal sensor 16b has a channel
71 that extends
to a vent 72 slightly behind the first metatarsal area of the insert 37, and
the first phalangeal
sensor 16a has a channel 71 that also extends to the same vent 72, via a
passageway that
includes traveling through the first metatarsal sensor 16b. In other words,
the first phalangeal
sensor 16a has a channel 71 that extends from the hole 43 at the first
phalangeal sensor 16a to
the hole 43 at the first metatarsal sensor 16b, and another channel 71 extends
from the first
metatarsal sensor 16b to the vent 72. The fifth metatarsal sensor 16c and the
heel sensor 16d
also share a common vent 72, located in the heel portion of the insert 37. One
channel 71
extends rearward from the hole 43 at the fifth metatarsal sensor 16c to the
vent 72, and
another channel 71 extends forward from the hole 43 at the heel sensor 16d to
the vent 72.
Sharing the vents 72 among multiple sensors can decrease expense, particularly
by avoiding
the need for additional filters 73. In other embodiments, the airflow system
70 may have a
different configuration, such as the configuration shown in FIGS. 22C-D and
discussed
below. In further embodiments, each sensor 16 may have its own individual vent
72, or more
than two sensors 16 may share the same vent 72.
[0047] Each vent 72 is formed as an opening in a bottom side of the second
layer 68 (i.e.
opposite the first layer 66), such that the opening permits outward flow of
air, moisture,
and/or debris from the airflow system 70, as seen in FIGS. 16-18 and 22A-B. In
another
embodiment, the vent 72 may include multiple openings. In a further
embodiment, the vent
72 may additionally or alternately be formed by an opening in the first layer
66, causing the
air to vent upwards out of the insert 37. In an additional embodiment, the
vent 72 may be on
the side (thin edge) of the insert 37, such as by extending the channel 71 to
the edge, such
that the channel 71 opens through the edge to the exterior of the insert 37.
The venting of the
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air downward, as in the embodiment illustrated in FIGS. 3-22B, 28, and 30,
makes it more
difficult for debris to enter the vent 72. The bottom layer 69, if present,
also includes
apertures 74 located below the vents 72, to permit the air flowing out of the
vents 72 to pass
through the bottom layer 69. The apertures 74 are significantly larger than
the vents 72, in
order to allow the filters 73 to be adhesively attached to the second layer 68
through the
bottom layer 69 around the periphery of each vent 72, as described below.
Additionally, in
this embodiment, each vent 72 has a reinforcement material 75 positioned
around the vent 72,
to add stability and strength to the material and prevent breaking/tearing. In
the embodiment
illustrated, the reinforcement material 75 is formed of the same material as
the leads 18 (e.g.
silver or other metallic iffl() to facilitate printing, but may also be formed
of the same material
as the sensor contacts 40, 42 (e.g. carbon) or the dielectric material
discussed herein.
[0048] The vents 72 in the embodiment illustrated in FIGS. 3-22B, 28, and
30 open
downward and the air passing through the vents 72 passes downward toward the
midsole 131
and toward the foam member 138 if present. In the embodiment illustrated in
FIGS. 3-5, 28,
and 30, the foam member 138 has cavities 76 located directly below the vents
72 and
configured such that the air exiting the vents passes into the respective
cavity 76. In the
embodiment illustrated in FIGS. 3-5, 28, and 30, each cavity 76 is formed as a
slot that
extends completely through the foam member 138, which may be formed by
punching,
cutting, or another technique. In another embodiment, the cavity 76 may be a
recess that
extends through only a portion of the foam member 138, or may extend deeper
than the foam
member 138, such as through at least a portion of a structure below the foam
member 138
(e.g. a strobel, midsole, etc.). In a further embodiment, the sole structure
may not contain the
foam member 138, and the cavity 76 may be formed at least in part by a slot,
recess, or other
cavity-like structure in another sole member, such as a strobel, midsole, etc.
As shown in
FIG. 5, at least a portion of the cavity 76 may be circular in one embodiment,
and may extend
wider than the vent 72 to provide space for air venting. This configuration
allows air to pass
out of the vents 72 without obstruction from the foam member 138. In another
embodiment,
the insert 37 may be positioned above another sole member (such as a portion
of the midsole
131), which may contain one or more cavities 76 as described above. In a
further
embodiment, no cavity may be present, and the air may vent 72 directly
downward into the
foam member 138 or other sole member. One or both of the cavities 76 may have
extending
portions that form passages 77 that further allow air to pass out of the
cavity 76. In the
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embodiment of FIGS. 3-5, 28, and 30, each of the cavities 76 has a channel
portion 77
extending laterally away from the cavity 76 and beyond the peripheral boundary
of the insert
37. In other words, the channel portion 77 of the cavity 76 extends laterally
from the vent 72
to a distal end 78 located outside the peripheral boundary of the insert 37.
It is understood
that if the foam member 138 has a recess 139 to receive the insert member 37,
the distal end
78 of the channel portion 77 of the cavity 76 may also be located outside the
peripheral
boundary of the recess 139. In the embodiment shown in FIGS. 3-5, the distal
end 78 extends
to the edge of the foam member 138. This configuration permits air passing
into the cavity
76 to exit the sole structure 130 by passing laterally through the channel
portion 77 and then
upward and/or outward away from the foam member 138. FIG. 28 shows a schematic
cross-
section of this configuration, with arrows illustrating the flow of air. The
configuration
illustrated in FIGS. 3-5, 28, and 30 permits air flow out of the vent 72, and
possibly back into
the vent 72, while resisting migration of debris (e.g. dirt, fibers, etc.) and
moisture from
migrating to and through the vent 72. The combined downward, lateral, and
upward paths
that the air must pass through to travel to and from the vent 72 acts to
resist this migration,
and debris will often become trapped near the distal end 78 of the cavity 76,
much like a
drain trap in a plumbing application.
[0049] In another embodiment, the distal end 78 may stop at a point within
the foam
member 138 and still outside the peripheral boundary of the insert 37, which
allows the air to
vent upward out of the cavity 76 at the distal end 78 and provides the same or
similar
functionality. FIGS. 36-38 and 47 illustrate an example embodiment of this
configuration. It
is understood that the foot contacting member 133 in the embodiments of FIGS.
36-38 and 47
may include passages positioned around the distal ends 78 of the cavities 76
to allow air
passage through the foot contacting member 133, such as the passages 79 shown
in FIGS. 28
and 30. In a further embodiment, at least a portion of the channel portion 77
may be a tunnel
within the foam member 138, rather than a slit. In such a configuration, the
channel portion
77 may have a tunnel portion and an open portion that permits air passing
through the tunnel
to vent upward, or the tunnel portion may extend all the way to the edge of
the foam member
138 to permit sideways venting. FIG. 29 shows a cross-section of an alternate
embodiment,
where the foam member 138 contains a cavity 76 but no channel portion 77.
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[0050] Additionally, the foot contacting member 133 includes one or more
passages 79
extending through the foot contacting member 133 located at the distal end 78
of the cavity
76, in the embodiment of FIGS. 3-5, 28, and 30. As shown in FIGS. 28 and 30,
the passages
79 may be pinhole-type passages 79 that extend vertically through the foot
contacting
member 133. In another embodiment, a different type of passage 79 may be used,
including
slits or grooves, and at least one passage 79 may extend laterally to a side
of the foot
contacting member 133, rather than upward through the thickness of the foot
contacting
member 133. The passages 79 allow the air exiting through the vent 72 and
outward through
the cavity 76 to pass through the foot contacting member 133 and out of the
sole structure
130. In another embodiment, the foot contacting member 133 may not include any
passage(s) 79. The foot contacting member 133 may still provide ventilation in
a
configuration without any passage(s) 79, such as by using a breathable foam or
other
breathable material for constructing the foot contacting member 133.
[0051] As described above, in one embodiment, the insert 37 may have one or
more
filters 73 that at least partially cover the vent(s) 72, as seen in FIGS. 22B
and 28-29. The
filter 73 may be considered to be a selectively permeable closure that covers
the vent 72,
which at least allows passage of air out of the vent 72 and resists passage of
certain
undesirable substances into the vent. For example, in the embodiment of FIGS.
3-22B, 28,
and 30, the filter 73 is a selectively permeable closure that permits inward
and outward flow
of air, and also permits outward flow of moisture, while resisting the inward
flow of moisture
and/or particles. One type of filter 73 that may achieve this function is a
fluoroplastic porous
membrane, for example, a porous membrane comprising PTFE (i.e. Teflon) fibers.
Such a
porous membrane may be a 10 m to 100 m thick porous membrane in one
embodiment. In
a filter 73 including PTFE fibers, the high surface energy of the PTFE causes
water to ball up
on the surface of the filter 73, rather than penetrating. The filter 73 may
also have an
adhesive on one side to permit the filter 73 to be connected to the insert 37,
and may further
have another material connected to either the inward or outward facing side,
such as a
polyester material to provide shear strength for the porous membrane. In the
embodiment
shown in FIGS. 3-22B, 28, and 30, the filter 73 is adhesively attached to the
bottom side of
the second layer 68 around the periphery of the vent 72 to cover the vent 72.
The bottom
layer 69 includes apertures 74 that are significantly larger than the vents
72, in order to allow
the filters 73 to be adhesively attached to the second layer 68, in the
embodiment of FIGS. 3-
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22B, 28, and 30. In other embodiments, a different type of filter 73 may be
used, and/or the
filter 73 may be connected to the insert 37 in another manner. In a further
embodiment, no
filter 73 may be used.
[0052] FIGS. 36-44 illustrate a sensor system 412 with an insert 437 that
includes an
airflow system 70 with a different arrangement of channels 71 and vents 72
than the insert 37
described above and shown in FIGS. 3-22B. FIGS. 22C-D and FIGS. 45-47
illustrate
additional embodiments of insert members 37', 537 that include an airflow
system 70 with a
channels 71 and vents 72 arranged similarly to the insert 437 of FIGS. 36-44.
The positions
of the sensors 16a-d in the embodiment of FIGS. 22C-D are generally the same
as in the
embodiment of FIGS. 3-22B, 28, and 30, and are illustrated in broken lines on
the spacer
layer 67 in FIG. 22C. Such structural features are not described again herein
for the sake of
brevity. In the embodiment of the insert 437 in FIGS. 36-44, the first
phalangeal sensor 16a
and the first metatarsal sensor 16b are connected to the same vent 72 by
channels 71 in
substantially the same configuration described above. The fifth metatarsal
sensor 16c and the
heel sensor 16d also share a common vent 72, which is located in the fifth
metatarsal area of
the insert 437, rather than in the heel portion as in the embodiment of FIGS.
3-22B, 28, and
30. In this configuration, the heel sensor 16d has a channel 71 that extends
from the hole 43
at the heel sensor 16d to the hole 43 at the fifth metatarsal sensor 16c, and
another channel 71
extends from the fifth metatarsal sensor 16c to the vent 72. As shown in FIGS.
36-44, the
locations of the vents 72 are different from the embodiment described above,
and
accordingly, the insert 437 may be used with a sole structure 130 that
contains features
specifically adapted for vents 72 in these locations. FIGS. 36-38 illustrate a
sole structure
130 and a foam member 138 that includes cavities 76 positioned for cooperation
with the
vents 72 of the insert 437. These cavities 76 function similarly to the
cavities 76 of the
embodiment shown in FIGS. 3-5 and described herein. For example, the foam
member 138
has a cavity 76 in the fifth metatarsal area of the sole structure 130
extending forward beyond
the peripheral edge of the insert 437 in order to provide venting of air from
the vent 72 in the
fifth metatarsal area of the insert 437. The foam member 138 also has a cavity
76 in the first
metatarsal area of the sole structure 130 extending rearward beyond the
peripheral edge of the
insert 437 in order to provide venting of air from the vent 72 in the first
metatarsal area of the
insert 437. The inserts 37', 537 of FIGS. 22C-D and 45-47 may utilize foam
members 138
with cavities 76 positioned in similar locations in various embodiments. It is
understood that
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different positions and configurations of cavities 76 may be utilized in other
embodiments.
In a further embodiment, a single sole structure 130 may contain multiple
cavities 76
arranged for use with several different types of inserts 37, 37', 437, 537
having different vent
72 locations. In this embodiment, at least some of the cavities 76 may be
unused, depending
on the configuration of the insert 37, et seq. In further embodiments, any of
the features,
characteristics, etc., of the embodiments of airflow systems 70 described
herein may be
combined with other embodiments of airflow systems 70, as well as other
embodiments of
sensor systems 12, inserts 37, and/or footwear 100.
[0053] In the embodiment of FIGS. 3-22B, as described above, the spacer
layer 67
generally insulates conductive members/components on the first and second
layers 66, 68
from each other, except in areas where electrical contact is desired, such as
at the pathway 50
and between the contacts 40, 42 of the sensors 16. The spacer layer 67 has
holes 38, 43 to
define areas of desired electrical contact between the layers 66, 68. The
components of the
airflow system 70, in particular the channels 71 may provide a route for
shorting or other
undesired electrical contact by one or more conductive members between the
first and second
layers 66, 68. In one embodiment, the sensor system 12 may include one or more
patches of
dielectric material 80 to resist or prevent undesired shorting by one or more
conductive
members across open areas of the spacer layer 67, such as the channels 71.
This dielectric
material 80 may be in the form of an acrylic ink or other UV-curable iffl(, or
another
insulating material suitable for the application. In the embodiment shown in
FIGS. 16-17, the
insert 37 has several patches of dielectric material 80 extending across the
channel 71, to
insulate the distribution leads 18A located around the sensor contacts 40, 42
from each other.
As shown in FIGS. 16-17, the dielectric material 80 is connected to the top
side of the second
layer 68 and covers the distribution lead 18A, although in another embodiment,
the dielectric
material 80 may be connected to the first layer 66, 68, or both layers may
have the dielectric
material 80. The spacer layer 67 may have a dielectric "bridge" over the
channel 71 in a
further embodiment. Additionally, the dielectric material completely covers a
portion of the
distribution lead 18A and is wider than the width of the channel 71, which
compensates for
movement or displacement of the spacer layer 67 or differences in
manufacturing tolerances.
In this embodiment, the insert 37 has patches of the dielectric material 80
located at each
intersection of one of the channels 71 with the distribution leads 18A,
including one patch 80
on the rear side of the first phalangeal sensor 16a, two patches 80 on the
front and rear ends
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of the first metatarsal sensor 16b, one patch 80 on the rear side of the fifth
metatarsal sensor
16c, and one patch 80 on the front side of the heel sensor 16d. In other
embodiments, the
insert 37 may have patches of the dielectric material located elsewhere on the
insert 37, to
insulate other portions of the distribution leads 18A or other conductive
members from
shorting between the layers 66, 68. It is understood that a spacer layer 67
having a different
configuration with holes, apertures, openings, etc. that are differently
shaped and/or located
may give rise to the use of the dielectric material 80 in other locations for
insulation
purposes. As discussed herein, the dielectric material 80 may be used in other
places as a
reinforcement or stiffening material.
[0054] In the embodiment of FIGS. 3-22B, the port 14, the sensors 16, and
the leads 18
form a circuit 10 on the insert member 37. The port 14 has a plurality of
terminals 11, with
four terminals 11 each dedicated to one of the four sensors 16 individually,
one terminal 11
for applying a voltage to the circuit 10, and one terminal 1 for voltage
measurement. In this
embodiment, the sensor system 12 also includes a pair of resistors 53, 54,
each located on one
of the layers 66, 68, and a pathway 50 connecting the circuitry on the first
layer 66 with the
circuitry on the second layer 68. The resistors 53, 54 provide a reference
point for the
module 22 to measure the resistance of each sensor 16, and permit the module
22 to convert
the variable current from the active sensor 16 into a measurable voltage.
Additionally, the
resistors 53, 54 are arranged in parallel within the circuit 10, which
compensates for
variations in the circuit 10 and/or variations in the manufacturing processes
used to create the
resistors 53, 54, such as variations in conductivity of the inks used to print
the leads 18 and/or
the sensor contacts 40, 42. In one embodiment, the equivalent resistance of
the two resistors
53, 54 is 1500 +/- 500 ka In another embodiment, a single resistor 53, 54 or
two resistors
53, 54 in series could be used. In a further embodiment, the resistors 53, 54
may be
positioned elsewhere on the insert 37, or may be located within the circuitry
of the module
22. A more technical depiction of the circuit 10 of this embodiment is
described below and
shown in FIG. 20.
[0055] FIG. 20 illustrates a circuit 10 that may be used to detect and
measure pressure in
accordance with an embodiment of the invention. The circuit 10 includes six
terminals 104a-
104f, including a power terminal 104a for applying a voltage to the circuit
10, a measurement
terminal 104b for measuring a voltage as described below, and four sensor
terminals 104c-
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104f, each of which is dedicated to one of the sensors 16a-16d individually,
and each of
which represents ground in this embodiment. The terminals 104a-104f represent
the
terminals 11 of the port 14. In the embodiment shown, fixed resistors 102a and
102b, which
represent resistors 53 and 54, are connected in parallel. Fixed resistors 102a
and 102b may
be physically located on separate layers. The equivalent resistance across
terminals 104a and
104b is determined by the well-known equation of:
Reg= RiO2a.R102b/(R102a+R102b) (Equation 1)
Where:
R102a¨ Resistance of fixed resistors 102a
R102b= Resistance of fixed resistors 102b
Reg= Equivalent resistance
[0056] Electrically connecting fixed resistors 102a and 102b in parallel
compensates for
variations in the manufacturing processes used to create fixed resistors 102a
and 102b. For
example, if fixed resistor 102a has a resistance that deviates from a desired
resistance, the
deviation of the equivalent resistance determined by equation 1 is minimized
by the
averaging effect of fixed resistor 102b. One skilled in the art will
appreciate that two fixed
resistors are shown for illustration purposes only. Additional fixed resistors
may be
connected in parallel and each fixed resistor may be formed on a different
layer.
[0057] In the embodiment shown in FIG. 20, fixed resistors 102a and 102b
are connected
to sensors 16a-16d. Sensors 16a-16d may be implemented with variable resistors
that change
resistance in response to changes in pressure, as described above. Each of
sensors 16a-16d
may be implemented with multiple variable resistors. In one embodiment, each
of sensors
16a-16d is implemented with two variable resistors which are physically
located on different
layers and electrically connected in parallel. For example, as described above
with respect to
one embodiment, each sensor 16a-16d may contain two contacts 40, 42 that
engage each
other to a greater degree as applied pressure increases, and the resistance of
the sensor 16a-
16d may decrease as the engagement increases. As mentioned above, connecting
resistors in
parallel creates an equivalent resistance that minimizes deviations created
during
manufacturing processes. In another embodiment, the contacts 40, 42 may be
arranged in
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series. Sensors 16a-16d may be connected to ground via switches 108a-108d.
Switches
108a-108d may be closed one at a time to connect a sensor. In some
embodiments, switches
108a-108d are implemented with transistors or integrated circuits.
[0058] In operation a voltage level, such as 3 volts, is applied at
terminal 104a. Switches
108a-108d are closed one at a time to connect one of sensors 16a-16d to
ground. When
connected to ground, each of sensors 16a-16d forms a voltage divider with the
combination
of fixed resistors 102a and 102b. For example, when switch 108a is closed, the
voltage
between terminal 104a and ground is divided between the combination of fixed
resistors 102a
and 102b and sensor 16a. The voltage measured at terminal 104b changes as the
resistance of
sensor 16a changes. As a result, pressure applied to sensor 16a may be
measured as a voltage
level at terminal 104b. The resistance of the sensor 16a is measured utilizing
the voltage
applied to the sensor 16a in series with the combined fixed resistors 104a and
104b of known
value. Similarly, selectively closing switches 108b-108d will generate voltage
levels at
terminal 104b that are related to the pressure applied at sensors 16b-16d. It
is understood that
the connections between the sensors 16a-d and the terminals 104c-f may be
different in other
embodiments. For example, the sensors 16a-d are connected to different pins of
the interface
20 in the left shoe insert 37 as compared to the right shoe insert 37, as
shown in FIG. 12. In
another embodiment, the voltage level may be applied in the opposite manner,
with the
ground located at terminal 104a and the voltage applied at terminals 104c-f.
In further
embodiments, another circuit configuration may be used to achieve a similar
result and
functionality.
[0059] The two resistors 53, 54 have similar or identical structures in the
embodiment
illustrated, however it is understood that the resistors may have different
structures in other
embodiments. Each resistor 53, 54 has two sections 55, 56 spaced from each
other and a
bridge 57 positioned between and connecting the sections 55, 56. FIGS. 15 and
17 illustrate
more detailed views of the resistors 53, 54, with one resistor 53 shown from
the top and the
other resistor 54 shown from the underside. The sections 55, 56 may be
connected to
different leads 18, such that an electronic signal or current that enters the
resistor 53, 54
through one lead 18 would travel between the sections 55, 56 across the bridge
57, and then
exit through the other lead 18. The sections 55, 56 may be formed as an inner
section 55 and
an outer section 56 that substantially surrounds the inner section 55, to
provide a large length
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for transmission between the sections 55, 56 within a small area. In this
embodiment, the
bridge 57 also substantially surrounds the inner section 55 and is
substantially surrounded by
the outer section 56. As seen and appreciated in FIGS. 15-17, the bridge 57
overlaps partially
with both the inner section 55 and the outer section 56, in order to permit
transmission
through the bridge 57. In the embodiment of FIGS. 15 and 17, the inner section
55 is formed
in a circular or substantially circular shape. The outer section 56 is at
least partially formed
by a semi-annular ring shape that at least partially surrounds the inner
section 55 and is
spaced from the inner section around the inner edge of the ring, in this
embodiment. The
bridge 57 in this embodiment is also at least partially formed by a semi-
annular ring shape
with inner and outer semi-circular edges, and the bridge 57 at least partially
surrounds the
inner section 55 and at least partially fills the spaces between the sections
55, 56. The inner
edge of the bridge 57 overlaps the inner section 55 and the outer edge of the
bridge 57
overlaps the outer section 56, as illustrated in FIG. 17. Additionally, in
this embodiment, a
gap 58 is defined through the outer section 56 and the bridge 57 to permit the
lead 18 to
connect to the inner section 55 and pass away from the inner section 55
without contacting
the outer section 56 or the bridge 57. In other words, the semi-annular ring-
shaped outer
section 56 and bridge 57 have ends that define the gap 58 therebetween. It is
understood that
the relative shapes, sizes, and arrangements of the sections 55, 56 and the
bridge 57 may be
different in other embodiments.
[0060] In one embodiment, the bridge 57 may be formed of a more resistive
material than
the sections 55, 56, and may thus provide the majority of the resistance of
each resistor 53,
54. The sections 55, 56 may be at least partially formed of a high-
conductivity material, such
as a silver material. In the embodiment illustrated in FIGS. 3-22B, the inner
and outer
sections 55, 56 are formed of the same material as the leads 18, such as a
printed silver-based
or other metallic-based ink. In this embodiment, the bridge 57 is formed of
the same material
as the sensor contacts 40, 42, such as carbon black or another conductive
carbon material. It
is understood that the inner and outer sections 55, 56 and/or the bridge 57
may be formed of
different materials in other embodiments.
[0061] The pathway 50 generally permits continuous and/or uninterrupted
electrical
communication and passes electronic signals between the first and second
layers 66, 68. In
the embodiment of FIGS. 3-22B, the port 14 is directly connected to the second
layer 68, and
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the pathway 50 may serve as a vertical path between the port 14 and the sensor
contacts 40 on
the first layer 66, 68. In this embodiment, the pathway 50 includes conductive
portions 51 on
the first layer 66 and the second layer 68, such that conductive portions 51
are in continuous
engagement with each other to provide continuous electrical communication
between the first
and second layers 66, 68 (See, e.g., FIG. 21). The spacer layer 67 in this
embodiment
includes a hole 38 that is aligned with the pathway 50 and allows for
continuous engagement
between the conductive portions 51 through the spacer layer 67. Additionally,
in the
embodiment of FIGS. 3-22B, each of the conductive portions 51 is divided into
two sections
52 that are separated by an elongated gap 59 (FIG. 15). These conductive
sections 52 have
substantially half-circular shapes in the embodiment shown in FIGS. 3-22B, and
the
conductive portions 51 have a generally circular shape. The sections 52 on the
first layer 66
are shaped, sized, and located substantially the same as the sections 52 on
the second layer
68, such that the sections on each layer 66, 68 engage the corresponding
sections 52 on the
other layer 66, 68. The gaps 59 on the two layers 66, 68 are also
substantially aligned in this
embodiment. In other words, the conductive portions 51 may be arranged so that
the left
sections 52 of the conductive portions 51 engage each other and the right
sections 52 of the
conductive portions 51 engage each other, with no direct engagement between
either of the
left sections 52 and either of the right sections 52. This configuration may
alternately be
described as creating two separate, side-by-side pathways between the first
and second layers
66, 68, and each section 52 may be considered to be separate conductive
portions forming
each pathway. The conductive portions 51 of the pathway 50 are formed of a
conductive
material, and in one embodiment, the conductive portions 51 may be formed of
the same
material as the leads 18, such as a silver-based ink or other metallic ink. In
other
embodiments, the pathway 50, and the components thereof described herein, may
have a
different size, shape, form, or location, and may be formed of a different
material.
[0062] The pathway 50 may be at least partially surrounded by or bounded by
a stiffening
structure 60 in one embodiment to provide structural support and/or effects.
As illustrated in
FIGS. 7-17 and 21, the conductive portions 51 are surrounded by a
substantially annular
stiffener 60. The stiffener 60 in this embodiment is not completely annular,
as the gap 59
extends through the stiffener 60, and the stiffener 60 may also include
additional gaps for
leads 18 to pass through and connect to the conductive portions 51, in another
embodiment.
The stiffener 60 in this embodiment serves to assist with engagement between
the conductive
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portions 51, to achieve maximum engagement between the conductive portions 51.
FIG. 21
illustrates this configuration in greater detail. It is understood that FIG.
21 is at least partially
schematic in nature, and the relative sizes of the components shown in FIG. 21
may be
exaggerated for effect and understanding. Additionally, FIG. 21 does not show
the bottom
layer 69, for clarity in illustrating the other layers 66, 67, 68. In general,
the spacer layer 67
provides separation between the conductive portions 51, such that the layers
66, 68 must be
deflected toward each other at the pathway 50 in order for the conductive
portions 51 to
engage each other.
[0063] In the embodiment shown in FIG. 21, the hole 38 in the spacer layer
67 permits
the conductive portions 51 to deflect toward each other and engage each other.
The first and
second layers 66, 68 may be vacuumed or otherwise pressed together to achieve
this contact,
such as by passing a roller over the assembled insert 37 at the location of
the pathway 50 to
remove excess air. The deflection of the layers 66, 68 toward each other
creates an annular
transition region 61 on one or both of the layers 66, 68 around the rim of the
hole 38, where
the layer or layers 66, 68 deflect toward each other. The transition region 61
in this
embodiment is defined by an outer annular break line 61a and an inner annular
break line
61b, with the transition region 61 between the break lines 61a, 61b, and with
the conductive
portions 51 within the inner break line 6 lb. In this configuration, the first
and second layers
66, 68 are generally horizontal outside the outer break line 61a and within
the inner break line
61a, and the first and second layers 66, 68 slope toward each other at the
transition region 61
to create engagement between the conductive portions 51. The hole 38 is larger
in dimension
than the stiffener 60, such that the stiffener 60 is positioned adjacent the
edge of the hole 38.
In this configuration, the increased stiffness of the stiffener 60 tends to
cause the layers 66, 68
to make a sharp transition from horizontal to at least partially vertical at
the location of the
stiffener 60, and thus the stiffener 60 tends to define the transition region
61.
[0064] As seen in FIG. 21, the location of the transition region 61 at the
stiffener 60
permits maximum contact between the conductive portions 51 inside the area 62
bounded by
the transition region 61. In one embodiment, majorities of the conductive
portions 51 are in
continuous engagement with each other through the hole 38 inside an area 62
bounded by the
transition region 61. In another embodiment, the conductive portions 51 are in
continuous
engagement with each other through the hole 38 over the entirety or
substantially the entirety
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of the area 62 bounded by the transition region 61. This continuous contact
assists in
ensuring that the pathway 50 and the circuit 10 will be uninterrupted and will
function
properly. Adhesives may be utilized at or around the pathway 50 to enhance the
engagement
between the layers 66, 68 at the pathway 50. The stiffener 60 may be formed of
any material
that has suitable stiffness, and in one embodiment, may be formed of a
material with greater
stiffness than the material of the conductive portions 51. One example of such
a material is
carbon black or other carbon-based material, although other materials may be
used in other
embodiments, including other types of printable substances.
[0065] The stiffener 60 may also assist in achieving continuous engagement
between the
conductive portions 51 in a different way. In the embodiment of FIGS. 3-22B,
the stiffener
60 is formed by a carbon-based iffl( that is more absorptive of many
wavelengths of light as
compared to the metallic-based iffl( of the conductive portions 51, which may
tend to be
reflective. The iffl( on the layers 66, 68 may be cured using IR radiation,
and in this
embodiment, the stiffener 60 may absorb a greater amount of the IR radiation
than the
conductive portions 51. This absorption may tend to heat the area of the layer
66, 68
immediately below the stiffener 60 to cause a temperature gradient across the
thickness of the
layer 66, 68, such that the layer 66, 68 is warmer on the surface on which the
stiffener 60 is
printed and cooler on the opposite surface. This temperature gradient, in
turn, may cause
differential expansion/contraction at the opposed surfaces of the layer 66, 68
around the
stiffener 60, such that the warmer surface at the stiffener 60 may contract
relative to the
surface opposite the stiffener 60, causing the region of each layer 66, 68
inside the stiffener
60 (i.e. at the conductive portions 51) to protrude or dimple slightly upward.
This protrusion
of the layers 66, 68 extends the conductive portions 51 on the layers 66, 68
closer to each
other, which may result in increased engagement between the conductive
portions 51,
assisting in achieving continuous or substantially continuous engagement of
the conductive
portions 51 within the stiffener 60. The protrusion of the layers 66, 68 may
additionally or
alternately be enhanced by mechanical stamping or other pre-straining action
to create a
protruding or dimpling effect. Bonding techniques, such as ultrasonic spot
welding or other
spot welding, may additionally or alternately be used increase engagement
between the
conductive portions 51. In one embodiment, ultrasonic spot welding may be used
in a waffle
pattern between the conductive portions 51 to retain the conductive portions
51 in
engagement with each other.
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[0066] The gap 59 in the pathway 50 may serve multiple functions. One
function that
may be served by the gap 59 is to create electrical separation between the
sections 52 of the
pathway 50, in order to create separate connections between the layers 66, 68.
Another
function that may be served by the gap 59 is to increase the durability of the
pathway 50
during flexing of the insert 37. In general, the foot of the user will tend to
"roll" from the
fifth metatarsal area (also referred to as the fifth metatarsal head area or
the fifth
metatarsophalangeal area) to the first metatarsal area (also referred to as
the first metatarsal
head area or the first metatarsophalangeal area). In the embodiment of FIGS. 3-
22B, the
pathway 50 is located around the second and/or third metatarsal areas of the
insert 37, so that
the roll of the user's foot passes directly over the pathway 50. Repeated
rolling of this nature
can cause bending of the conductive portions 51, which can in turn, cause
abrasion, fracture,
separation, etc. The gap 59 can serve as a flexing point to minimize bending
of the
conductive portions 51 if aligned properly. In the embodiment of FIGS. 3-22B,
the gap 59 is
generally aligned perpendicular to the direction of the typical roll of the
user's foot, or in
other words, perpendicular to a line extending between the fifth metatarsal
area and the first
metatarsal area of the insert 37. In one embodiment, a virtual line L (see
FIG. 10) may be
drawn between the sensor 16b in the first metatarsal area and the sensor 16c
in the fifth
metatarsal area, and the gap 59 may be aligned perpendicular to this line L or
within +/- 450
of being perpendicular to the line L. The line L as shown in FIG. 10 is drawn
between the
front edge (e.g. front center) of the first metatarsal sensor 16b and the rear
edge (e.g. rear
center) of the fifth metatarsal sensor 16c. In other embodiments, the gap 59
(if present) may
be positioned differently, particularly if the pathway 50 is located in a
different area of the
insert 37.
[0067] FIGS. 52-56 illustrate another embodiment of a sensor system 612
that includes
an insert member 37, which are similar to the sensor system 12 and the insert
37 of FIGS. 3-
22B. In the embodiment of FIGS. 52-56, the pathway 50 does not include a
stiffener 60 as in
the embodiment of FIGS. 3-22B. Additionally, the conductive portions 51 of the
pathway 50
in this embodiment are enlarged to cover the area that is covered by the
stiffener 60 in the
embodiment of FIGS. 3-22B. In other words, in this embodiment, the conductive
portions 51
extend almost to the edge of the hole 38 that is aligned with the pathway 50,
and portions of
the conductive portions 51 are positioned within the transition region 61, as
illustrated
schematically in FIG. 56. The increased sizes of the conductive portions 51 in
the
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embodiment of FIGS. 52-56 may provide a greater surface area for potential
engagement
between the conductive portions 51, and thereby provide more consistent and
uninterrupted
function of the pathway 50. In other respects, the pathway 50 shares
structural and functional
features with the embodiments of the pathway 50 shown in FIGS. 3-22B and
described
elsewhere herein. Such similar structures and functions are not described
again for the sake of
brevity. In one embodiment, mechanical stamping or other pre-straining action
can be used to
create a protruding or dimpling effect of the layers 66, 68, enhancing
engagement between
the conductive portions 51, as described above. Bonding techniques, such as
ultrasonic spot
welding or other spot welding, may additionally or alternately be used
increase engagement
between the conductive portions 51, as also described above.
[0068] In another embodiment, the pathway 50 may be positioned in another
location or
have another configuration. For example, in one embodiment, the pathway 50 may
be
formed at or near the terminals 11, such as by utilizing a two-pin connection
(not shown) on
the first layer 66 and connecting the two-pin connection to the fifth and
sixth terminals 11 of
the interface 20, such as by a crimping connection. Other structures for
forming a pathway
50 may be utilized in further embodiments.
[0069] FIGS. 48-51 illustrate another embodiment of a sensor system 712
that is
configured differently than the sensor systems 12, 412, 512, 612 described
herein and has a
different mode of operation compared to the sensor systems 12, 412, 512, 612
described
herein. The sensor system 712 of FIGS. 48-51 includes many structural and
functional
features in common with the sensor system 12 described above and shown in
FIGS. 3-22B.
For example, the external shape of the insert 37, the general positions of the
sensors 16, and
the configuration of the airflow system 70 in the embodiment of FIGS. 48-51
are similar or
identical to the shape of the insert 37, the general positions of the sensors
16, and the
configuration of the airflow system 70 in FIGS. 3-22B. These and other such
common
features may not be described again herein for the sake of brevity.
[0070] In the embodiment of FIGS. 48-51, the sensor system 712 has sensors
16 that
include two contacts or electrodes 740, 742 positioned on the second layer 68
and a third
contact 744 positioned on the first layer 66. In this embodiment, all the
contacts 40, 742, 744
are formed of a carbon-based ink as described above, having one or more
distribution leads
18A at the edges of each of the contacts 740, 742, 744. The contacts 740, 742
on the second
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layer 68 may have a different conductivity than the contacts 744 on the first
layer 66, and
may be formed of a carbon-based ink that is doped to achieve higher
conductivity. The
contacts 740, 742 on the second layer 68 are electrically separate from each
other and are
each connected to the port 14 by leads 18. A single power or ground lead 18B
connects to a
first contact 740 of all of the sensors 16, and the second contact 742 of each
individual sensor
16 is connected by an individual lead 18 to the port 14.
[0071] The structures of the sensors 16 in the sensor system 712 of FIGS.
48-51 are
otherwise similar to the sensors 16 in the embodiment of FIGS. 3-22B. In this
embodiment,
the combined first and second contacts 740, 742 are structured similarly to
the contact 42 on
the second layer 68 of the embodiment of FIGS. 3-22B, except that the first
and second
contacts 740, 742 are electrically separate from each other and the third
contact 744 is
structured similarly to the contact 40 on the first layer 66 in the embodiment
of FIGS. 3-22B.
In other embodiments, the sensors 16 and/or the contacts 740, 742, 744 may
have different
configurations. For example, in one embodiment, the contact 744 on the first
layer 66 may
be a single patch of the carbon-based iffl(.
[0072] In the embodiment of the sensor system 712 in FIGS. 48-51, the first
and second
contacts 740, 742 are electrically separate from each other, and the third
contact 744 is in
confronting relation to the first and second contacts 740, 742, such that the
third contact 744
engages the first and second contacts 740, 742 upon application of vertical
pressure to the
sensor 16. In this configuration, the signals from the port 14 travel between
the two
electrodes 740, 742 of each sensor 16 on the second layer 68 by passing
through the electrode
744 of that sensor 16 on the first layer 66. Accordingly, the resistivity of
the sensor 16 is
determined by the engagement between the contacts 740, 742 on the second layer
68 and the
electrode 744 on the first layer 66, and the relationship between the pressure
applied to the
sensor 16 and the resistance of the sensor 16 is similar to that of the
sensors 16 of the
embodiment in FIGS. 3-22B described herein and shown in FIG. 27. The
sensitivity range,
activation pressure, and other functional properties of the sensors 16 of
FIGS. 48-51 may
also be similar to those of the sensors 16 of the sensor system 12 in FIGS. 3-
22B.
[0073] The connections at the port 14 in the sensor system 712 of FIGS. 49-
51 are similar
to those in the embodiment of FIGS. 3-22B and illustrated schematically in
FIG. 20,
including a power terminal 104a, a measurement terminal 104b, and four sensor
terminals
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104c-f. Resistivity/resistance measurements may be completed in the same or a
similar
manner as described above. The circuit in the embodiment of FIGS. 48-51 is
similar to that
shown in FIG. 20, however this embodiment includes only a single fixed
resistor 53, rather
than two fixed resistors 53, 54 in parallel as in the embodiment of FIGS. 3-
22B.
Additionally, each sensor 16 in the embodiment of FIGS. 3-22B may be
considered to be five
resistors in parallel, while each sensor 16 in the sensor system 712 of FIGS.
49-51 may be
considered to be two resistors in parallel (contact 742) arranged in series
with three additional
resistors in parallel (contact 740). In another embodiment, the sensor system
712 of FIGS.
48-51 may be wired to have two fixed resistors in parallel or any other
resistor configuration
described herein. It is understood that because the leads 18 connected to the
port 14 exist on
only the second layer 68, no pathway 50 between the layers 66, 68 is necessary
in this
embodiment. Accordingly, the spacer layer 67 in the sensor system 712 of FIGS.
48-51 may
not contain the hole 38 as in the spacer layer 67 of FIGS. 3-22B.
[0074] The insert 37 may be constructed by depositing the various
components on a
polymer (e.g. PET) film. In one embodiment, the insert 37 is constructed by
first depositing
the conductive metallic material on each layer 66, 68, such as by printing in
the traced pattern
of the leads 18 (including the distribution lead 18A, the conductive portions
51 of the
pathway 50, the inner and outer sections 55, 56 of the resistors 53, 54, etc.
The additional
carbon material can then be deposited on each layer 66, 68, such as by
printing, to form the
contacts 40, 42, the stiffener 60 of the pathway 50, the bridge 57 of the
resistors 53, 54, etc.
Any additional components can then be deposited, such as any dielectric
portions. The layers
66, 68 may be printed on PET sheets and then cut out to form the outer
peripheral shape after
printing in one embodiment.
[0075] The port 14 is configured for communication of data collected by the
sensors 16 to
an outside source, in one or more known manners. In one embodiment, the port
14 is a
universal communication port, configured for communication of data in a
universally
readable format. In the embodiments shown in FIGS. 3-22B, the port 14 includes
an
interface 20 for connection to an electronic module 22, shown in connection
with the port 14
in FIG. 3. Additionally, in this embodiment, the port 14 is associated with
the housing 24 for
insertion of the electronic module 22, located in the well 135 in the middle
arch or midfoot
region of the midsole 131. As illustrated in FIGS. 7-16, the sensor leads 18
converge
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together to form a consolidated interface 20 at their terminals 11, in order
to connect to the
port 14. In one embodiment, the consolidated interface may include individual
connection of
the sensor leads 18 to the port interface 20, such as through a plurality of
electrical contacts.
In another embodiment, the sensor leads 18 could be consolidated to form an
external
interface, such as a plug-type interface or another configuration, and in a
further embodiment,
the sensor leads 18 may form a non-consolidated interface, with each lead 18
having its own
separate terminal 11. As also described below, the module 22 may have an
interface 23 for
connection to the port interface 20 and/or the sensor leads 18.
[0076] In the embodiment shown in FIGS. 3-22B, the interface 20 takes the
form of
electrical contacts or terminals 11. In one embodiment, the terminals 11 are
formed on a
tongue or extension 21 that extends from one of the layers 66, 68 into the
hole 27 provided
for the housing 24. The extension consolidates the ends of the leads 18 to a
single area to
form the interface 20. In the embodiment of FIGS. 3-22B, the extension 21
extends from the
second layer 68 into the hole 27, and is bent downward within the housing 24
to place the
terminals 11 within the housing 24 and make the interface 20 accessible within
the housing
24. The second layer 68 further has slits 83 on both sides of the extension 21
in this
embodiment, to increase the length of the extension 21 and permit the
extension 21 to be bent
downwardly and extend down into the housing 24. The rounded ends of the slits
83 can resist
formation and/or propagation of cracks and tears in the material of the second
layer 68
around the extension 21. The extension 21 may pass underneath the flange 28 of
the housing
24 and through a slot or other space underneath the lip 28 in order to extend
into the housing
24. When the flange 28 is a separate piece, such as in the embodiment shown in
FIGS. 31-
32, the extension 21 may be inserted between the flange 28 and the tub 29
before the flange
28 is connected to the tub 29. In the embodiment shown in FIGS. 3-22B, the
extension 21 is
formed of the same polymeric film material as the second layer 68 and is
integral (e.g.
formed as a single piece) with the second layer 68. In other embodiments, the
extension 21
may extend from the first layer 66, may include portions connected to both
layers 66, 68,
and/or may be formed of a separate piece that is connected to one or both
layers.
[0077] The extension 21 as illustrated in FIGS. 3-22B and 32 has a
reinforcing material
81 that is connected to the extension to reinforce a portion of the extension
21. This
reinforcing material 81 may be selected from a number of different materials
that provide
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strength, stiffness, wear resistance, and other reinforcement. For example,
the reinforcing
material 81 may be formed of the same material as the dielectric material 80
used to insulate
between the layers 66, 68 at the channels 71, such as an acrylic ink or other
UV-curable ink.
In the embodiment illustrated in FIGS. 3-22B and 32, the reinforcing material
81 is in the
form of an elongated strip that extends across the entire width of the
extension 21 midway
along the length of the extension 21. The extension 21 in this embodiment
extends from the
second layer 68 into the hole 27, and the reinforcing material 81 is deposited
on the top side
of the extension 21, extending over and across the ends of the leads 18. The
reinforcing
material 81 may have a stiffness that is greater than the stiffness of the
material of the leads
18 in one embodiment, and may also have a greater stiffness than the film
material forming
the layers 66, 68 in another embodiment.
[0078] In the configuration illustrated in FIGS. 3-22B and 32, the
extension 21 bends
downwardly into the well 135 and into the housing 24, as discussed above, to
place the
terminals 11 within the housing 24 and forming the interface 20 within the
housing 24. As
shown in FIG. 32, the extension 21 has a bend area 84 where the extension 21
bends
downwardly at the peripheral edge of the housing 24, to extend downwardly
along the side
wall 25 of the housing 24. The bend area 84 is generally linear and extends
transversely
across the extension 21. In the embodiment illustrated, the reinforcing
material 81 is located
on the extension 21 such that the strip of reinforcing material 81 extends
transversely across
the extension 21 at the bend area 84 and generally parallel to the bend area
84. In one
embodiment, the reinforcing material 81 is formed as an elongated rectangular
strip and has a
width that is sufficient so that the reinforcing material 81 covers the entire
bend area 84. In
this position, the reinforcing material 81 serves several functions. One such
function is
protecting the leads 18 and/or the film of the extension 21 from damage due to
the bending of
the extension 21. Another such function is protecting the leads 18 and/or the
film of the
extension 21 from wear and abrasion at the bend area 84, such as from rubbing
against the
housing 24 at that location. A further such function is to add stiffness
and/or strength to the
extension 21. Other benefits of the reinforcing material 81 may be apparent to
those skilled
in the art. It is understood that, in other embodiments, the reinforcing
material 81 may be
positioned, shaped, or configured differently, or the reinforcing material 81
may additionally
or alternately be used in a different location to impart strength, stiffness,
wear resistance, etc.
to another component of the sensor assembly 12. In a further embodiment, no
reinforcing
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material 81 may be used, or the majority of the extension 21 may be covered by
the
reinforcing material 81.
[0079] The housing 24 may contain connection structure, such as connector
pins or
springs (not shown) for establishing connection between the interface 20 and
the module 22.
In one embodiment, the port 14 includes an electrical connector 82 forming the
interface 20,
which may include contacts that individually attach to the terminals 11, as
mentioned above
and shown in FIG. 32. The connector 82 may connect to the extension 21 and the
terminals
11 via a crimping connection. The interface 20 in this embodiment includes
seven terminals:
four terminals 11 each individually connected to one of the sensors 16, one
terminal 11
serving as the measurement terminal (104b in FIG. 20), and one terminal
serving as a power
terminal (104a in FIG. 20) to apply a voltage to the circuit 10. As discussed
above, the power
terminal may instead be configured as a ground terminal in another embodiment,
with the
sensor terminals (104c-f in FIG. 20) being configured as power terminals. As
illustrated in
FIG. 12, the arrangement of the sensors 16, the leads 18, and other components
of the sensor
system 12 may be different between the left and right foot inserts 37, and the
sensors 16 may
be connected to different terminals 11 in the left insert 37 as compared to
the right insert 37.
In this embodiment, the first four terminals 11 are still reserved for
connection to the sensors
16 (albeit in potentially a different order), with the fifth, sixth, and
seventh terminals 11
retaining the same function in both the left and right inserts 37. This
configuration may be
different in other embodiments. In another embodiment, the module 22 may be
specifically
configured for use with a left or right shoe 100 and insert 37. The seventh
terminal may be
utilized for powering of accessories, such as a unique identification chip. In
one
embodiment, the sixth and seventh terminals 11 are extended on a tail 21A that
extends from
the end of the extension 21. An accessory may be connected across the two
terminals 11 on
the tail 21A to power the accessory. The accessory may include a small printed
circuit board
(PCB) with a memory chip that are attached via anisotropic contact formation
to the tail 21A.
In one embodiment, an accessory chip may include information uniquely
identifying the
article of footwear 100, such as a serial number, as well as substantive
information such as
whether the footwear 100 is a left or right shoe, a men's or women's shoe, a
specific type of
shoe (e.g. running, tennis, basketball, etc.), and other types of information.
This information
may be read by the module 22 and subsequently used in analysis, presentation,
and/or
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organization of data from the sensors. The accessory may be sealed into the
housing 24, such
as via epoxy or other material.
100801 The
port 14 is adapted for connection to a variety of different electronic modules
22, which may be as simple as a memory component (e.g., a flash drive) or
which may
contain more complex features. It is understood that the module 22 could be as
complex a
component as a personal computer, mobile device, server, etc. The port 14 is
configured for
transmitting data gathered by the sensors 16 to the module 22 for storage,
transmission,
and/or processing. In some embodiments, the port 14, the sensors 16, and/or
other
components of the sensor system 12 may be configured for processing the data.
The port 14,
sensors 16, and/or other components of the sensor system 12 may additionally
or alternately
be configured for transmission of data directly to an external device 110 or a
plurality of
modules 22 and/or external devices 110. It is understood that the port 14, the
sensors 16,
and/or other components of the sensor system 12 may include appropriate
hardware,
software, etc., for these purposes. Examples of a housing and electronic
modules in a
footwear article are illustrated in U.S. Patent Application Serial No.
11/416,458, published as
U.S. Patent Application Publication No. 2007/0260421.
Although the port 14 is illustrated with electronic terminals 11
forming an interface 20 for connection to a module 22, in other embodiments,
the port 14
may contain one or more additional or alternate communication interfaces. For
example, the
port 14 may contain or comprise a USB port, a Firewire port, 16-pin port, or
other type of
physical contact-based connection, or may include a wireless or contactless
communication
interface, such as an interface for Wi-Fi, Bluetooth, near-field
communication, RFID,
Bluetooth Low Energy, Zigbee, or other wireless communication technique, or an
interface
for infrared or other optical communication technique. In another embodiment,
the sensor
system 12 may include more than one port 14 configured for communication with
one or
more modules 22 or external devices 110. This configuration may alternately be
considered
to be a single distributed port 14. For example, each of the sensors 16 may
have a separate
port 14 for communication with one or more electronic modules 22, as in the
embodiment of
the sensor system 812 illustrated in FIG. 61. The separate ports 14 may be
configured for
wireless communication using wireless or contactless communications as
described above.
In one embodiment, each port 14 may include an RFID chip with an antenna, and
in another
embodiment, the port(s) 14 may utilize the user's body as a transmission
system, transmitting
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information from the user's feet to a module 22 located elsewhere on the
user's body. The
ports 14 in this embodiment are connected to the sensors 16 by leads 18, and
it is understood
that the leads 18 in broken lines in FIG. 61 represent leads 18 on a lower
layer of the insert
37. The ports 14 may be located between the layers of the insert 37, within a
hole in the
insert 37, or above or below the insert 37 in various embodiments. It is
understood that
multiple or distributed port(s) 14 may be used, with combinations of two or
more sensors
connected to a single port 14. In further embodiments, the sensor system 12
may include one
or more ports 14 having different configurations, which may include a
combination of two or
more configurations described herein.
[0081] The module 22 may additionally have one or multiple communication
interfaces
for connecting to an external device 110 to transmit the data for processing,
as described
below and shown in FIGS. 6 and 23. Such interfaces can include any of the
contacted or
contactless interfaces described above. In one example, the module 22 includes
at least a
retractable USB connection for connection to a computer and/or for charging a
battery of the
module 22. In another example, the module 22 may be configured for contacted
or
contactless connection to a mobile device, such as a watch, cell phone,
portable music player,
etc. The module 22 may be configured for wireless communication with the
external device
110, which allows the device 22 to remain in the footwear 100. However, in
another
embodiment, the module 22 may be configured to be removed from the footwear
100 to be
directly connected to the external device 110 for data transfer, such as by
the retractable USB
connection described above. In a wireless embodiment, the module 22 may be
connected to
an antenna for wireless communication. The antenna may be shaped, sized, and
positioned
for use with the appropriate transmission frequency for the selected wireless
communication
method. Additionally, the antenna may be located internally within the module
22 or external
to the module. In one example, the sensor system 12 itself (such as the leads
18 and
conductive portions of the sensors 16) could be used to form an antenna. The
module 22 may
further be placed, positioned, and/or configured in order to improve antenna
reception, and in
one embodiment, may use a portion of the user's body as an antenna. In one
embodiment,
the module 22 may be permanently mounted within the footwear 100, or
alternately may be
removable at the option of the user and capable of remaining in the footwear
100 if desired.
Additionally, as further explained below, the module 22 may be removed and
replaced with
another module 22 programmed and/or configured for gathering and/or utilizing
data from
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the sensors 16 in another manner. If the module 22 is permanently mounted
within the
footwear 100, the sensor system 12 may further contain an external port (not
shown) to allow
for data transfer and/or battery charging, such as a USB or Firewire port. It
is understood that
the module 22 may be configured for both contacted and contactless
communication.
[0082] While the port 14 may be located in a variety of positions without
departing from
the invention, in one embodiment, the port 14 is provided at a position and
orientation and/or
is otherwise structured so as to avoid or minimize contact with and/or
irritation of the
wearer's foot, e.g., as the wearer steps down in and/or otherwise uses the
article of footwear
100, such as during an athletic activity. The positioning of the port 14 in
FIGS. 3-4 illustrates
one such example. In another embodiment, the port 14 is located proximate the
heel or instep
regions of the shoe 100. Other features of the footwear structure 100 may help
reduce or
avoid contact between the wearer's foot and the port 14 (or an element
connected to the port
14) and improve the overall comfort of the footwear structure 100. For
example, as described
above and illustrated in FIGS. 3-5, the foot contacting member 133 may fit
over and at least
partially cover the port 14, thereby providing a layer of padding between the
wearer's foot
and the port 14. Additional features for reducing contact between and
modulating any
undesired feel of the port 14 at the wearer's foot may be used. If desired,
the opening to the
port 14 may be provided through the top surface of the foot contacting member
133 without
departing from the invention. Such a construction may be used, for example,
when the
housing 24, electronic module 22, and other features of the port 14 include
structures and/or
are made from materials so as to modulate the feel at the user's foot, when
additional comfort
and feel modulating elements are provided, etc. Any of the various features
described above
that help reduce or avoid contact between the wearer's foot and a housing (or
an element
received in the housing) and improve the overall comfort of the footwear
structure may be
provided without departing from this invention, including the various features
described
above in conjunction with the attached figures, as well as other known methods
and
techniques.
[0083] FIGS. 62-76 disclose further views of one embodiment of the port 14
configured
to be utilized with the insert member 37. Similar structures described above
will be
designated with identical or similar reference numerals. This embodiment and
variations of
the embodiment are described in detail below. As discussed and disclosed
herein, the port 14
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defines or supports an interface 20 for an operable connection with the module
22. The
module 22 will also be described in greater detail below. Through the operable
connection
between the port 14 and the module 22, data sensed by the sensor assembly 12
can be
acquired, stored and/or processed for further use and analysis.
[0084] As appreciated from FIGS. 62-64, the port 14 is generally supported
at a mid-
portion of the insert assembly 37. The port 14 generally includes the housing
24 that
supports an interface assembly 156. As will be described in greater detail
below, the
interface assembly 156 is operably connected to the extension 21 having the
leads 11 thereon
of the insert member 37. With such connection, the interface 20 is established
for further
operable connection with the interface 23 of the module 22.
[0085] As further shown in FIGS. 65-67, the housing 24 in this embodiment
includes a
base member 140 and a cover member 142. The base member 140 may correspond to
the tub
29 as described above that defines the side walls 25 and the base wall 26. A
first end of the
base member 140 has a generally squared configuration that receives the
extension 21 of the
insert member 37. A second end of the base member 140 has a rounded
configuration. The
base member 140 defines a first section 144 and a second section 146. The
first section 144
is generally dimensioned to correspond in shape and receive the module 22, and
the second
section 146 is dimensioned to receive and support the interface assembly 156.
The second
section 146 further has a first lateral slot 148 and a second lateral slot 150
that are in
communication with one another. The first lateral slot 148 may extend wider
and be larger
than the second lateral slot 150. The housing 24 further defines a projection
151 at the
second end for retaining the module 22 in the housing 24. The finger recess
29A is generally
positioned proximate the projection 151. The base member 140 further has a
pair of receivers
152 for cooperation with the cover member 142.
[0086] As further shown in FIGS. 66-67, the cover member 142 has a central
aperture
153 dimensioned to receive the module 22 therethrough. The cover member 142
further has
a beam member 154 at a first end and a second end of the cover member 142 has
a rounded
configuration. The beam member 154 overhangs above a portion of the first
section 144
when connected to the base member 140 as will be described. An underside of
the cover
member 142 has a pair of depending posts 155 that cooperate with the receivers
152 on the
base member 140 as will be described. An outer periphery of the cover member
142 defines
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the lip or flange 28. In an exemplary embodiment, the cover member 142 may
have
depending walls that cooperatively define the side walls 25 of the housing 24.
In such
configuration, the base member 140 may define a ledge on the side wall to
receive the
depending walls on the cover member 142.
[0087] FIGS. 68-71 further show components of the interface assembly 156.
The
interface assembly 156 has a carrier 157 that supports the electrical
connectors 82 such as
described schematically in reference to FIG. 32. The electrical connectors 82
each have a
distal end defining a contact that is resiliently supported by the carrier 157
that will cooperate
with a corresponding contact on the module 22. The electrical connectors 82
have bends
around the carrier 157 and have proximate ends having a plurality of fingers
158 thereon. In
one embodiment, four fingers 158 are associated with each connector 82, and
the fingers 158
may be arranged in a flower-petal arrangement. As explained in greater detail
below, the
interface assembly 156 may further include a filler material 159 or potting
compound 159. It
is also understood that ends 82A of the connectors are snapped off at a
predetermined
location prior to connection with the extension 21 of the insert member 37, as
shown in FIG.
69.
[0088] As shown in FIGS. 72-73, the interface assembly 156 is operably
connected to the
extension 21 having the leads 11 thereon of the insert member 37. To that end,
the fingers
158 are connected to the extension 21 where there is engagement between the
leads 11 and
the connectors 82. This engagement can be seen and appreciated from FIG. 72
and also
understood from FIG. 32. In an exemplary embodiment, the fingers 158 protrude
through the
extension 21, wherein each plurality of fingers 158 extend through and engage
the extension
21 in a circumferential manner. As further shown in FIGS. 72, it is understood
that the tail
21A can be further folded over to be positioned adjacent a back side of the
extension 21. As
discussed, the tail 21A having the sixth and seventh connectors may have a PCB
member 90,
which may be an unique identification chip, connected thereto to function as
previously
described. It is understood that the extension 21 and carrier 157 are
positioned to depend
from an upper planar surface of the insert member 37. As further shown in FIG.
74, the
carrier 157 is positioned in the first lateral slot 148 of the base member 140
of the housing 24.
The carrier 157 is dimensioned to fit snugly and be retained in the first
lateral slot 148. The
connectors 82 face into the first section 144 defined by the housing 24. As
can be
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appreciated from FIGS. 75-76, it is understood that the filler material 159 or
potting
compound 159 may be injected into the second lateral slot 150 through an
opening 150A
(FIG. 65) in the base member 140 proximate the second lateral slot 150. The
potting
compound 159 may be a thermosetting plastic in an exemplary embodiment and
could also be
one or more other materials. The potting compound 159 fills the second lateral
slot 150 and
extends around the area wherein the extension 21 is connected to the
connectors 82 held by
the carrier 157, thus providing a protective connection. In one embodiment,
the potting
compound 159 maintains a desired amount of flexibility to enhance the
connection between
the extension 21 and the port 14. The potting compound 159 can resist shock
and vibration
while also resisting moisture ingress and corrosive agents. It is further
understood that the
base member 140 is positioned at the insert member 37 wherein the receivers
152 align with
corresponding openings 28B through the insert member 37. The cover member 142
is
positioned on the top surface of the insert member 37 wherein the depending
posts 155 fit
into the receivers 152 (FIGS. 62-67). An ultrasonic welding operation is
performed to
connect the cover member 142 to the base member 140. This connection is
similar to the
connection of the pegs 28A as shown in FIG. 31. Other connection techniques
for connecting
the cover member 142 to the base member 140 may be utilized in other
embodiments,
including snapping connections or other mechanical connections. It is
understood that the
beam member 154 extends over the interface 20 wherein the connectors 82 are
protected in
the housing 24. This configuration provides a robust connection of the port 14
to the insert
member 37 and for further operable connection with the module 22 as described
herein.
[0089] FIGS. 77-90 disclose additional views and features of one embodiment
of the
module 22, which is described in greater detail below. As previously
discussed, the module
22 is received by and is operably connected to the port 14 to collect, store
and/or process data
received from the sensor assembly 12. It is understood that the module 22
houses various
components for such purposes including but not limited to, printed circuit
boards, power
supplies, light members, interfaces, and different types of sensors, including
multi-axis
accelerometer, gyroscopes and/or magnetometers.
[0090] The module 22 generally includes a housing 170 that supports an
interface 23
having electrical connectors that form contacts for cooperation with the
interface 20 of the
port 14. As explained in greater detail below, the contacts associated with
the interface 23 of
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the module 22 are formed such that they are in a sealed configuration to
protect against
moisture ingress. The module 22 further has a dead-fronted LED light indicator
that is only
visually perceptible upon illumination. Finally, the module 22 utilizes a
unique ground plane
extender that enhances operation of the module 22.
[0091] As shown in FIGS. 79-83, the housing 170 of the module 22 supports
an interface
assembly 171. The interface assembly 171 has a plurality of connectors 172 and
a module
carrier 173. The connectors 172 each have distal ends that form contacts that
collectively
define the interface 23 of the module 22. It is understood that the connectors
172 are insert
molded such that material is formed around the connectors 172 to define the
module carrier
173. It is also understood that portions 172A (FIG. 79) of the connectors 172
are snapped off
at a predetermined location to place the connectors 172 at a proper length for
further operable
connection. The housing 170 generally has a module base member 174 having an
outer base
member 175 and an inner base member 176. The housing 170 further has a module
top
member 177 having an outer top member 178 and an inner top member 179. The
module
base members 175, 176, the module top members 178, 179 and interface assembly
171
cooperate to provide a sealed configuration around the connectors 172. The
connectors 172
may be considered to have an over-molded configuration. These components also
form an
inner cavity wherein the housing 170 supports internal components including a
printed circuit
board 180 that is operably connected to the connectors 172.
[0092] As discussed, the connectors 172 are insert molded wherein the
module carrier
173 is formed around the connectors 172. It is understood that the outer base
member 175 is
formed such as in an injection-molding process and defines an end opening. In
such process,
the connectors 172 can be sufficiently supported in the mold to withstand the
pressures
associated with the injection-molding process. The interface assembly 171 and
outer base
member 175 are placed in a mold wherein the interface assembly 171 is
positioned at the end
opening and supported by the outer base member 175. In a further injection-
molding process,
additional material is injected into the mold to form inner base member 176.
The inner base
member 176 is formed around the module carrier 173 and distal ends of the
connectors 172
and further against surfaces of the outer base member 175. An internal cavity
is defined by
the inner base member 176 wherein the printed circuit board 180 is supported
therein as is
known. It is understood that the connectors 172 are operably connected to the
printed circuit
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board 180. It is further understood that other components of the module 22 are
supported in
the internal cavity. As explained in greater detail below, the connectors 172
are configured in
a sealed fashion from the over-molding process.
[0093] The module top member 177 as shown in FIGS. 85-86 and 89-90,
including an
inner top member 179 and an outer top member 178, may also be formed using an
injection
technique in one embodiment. As shown in FIG. 88, the inner top member 179 has
an
aperture 181 therethrough. The outer top member 178 is generally a planar
member. The
inner top member 179 is positioned over the base member 174 and the outer top
member 178
is positioned over the inner top member 179. The top member 177 is connected
to the base
member 175 to encase the internal components of the module 22.
[0094] With this structural configuration, the connectors 172 are sealed to
prevent
potential moisture ingress. As shown in FIG. 84, the carrier 173 is in surface-
to-surface
engagement with the connectors 172 generally at inner surfaces of the
connectors 172. In
addition, the inner base member 176 is positioned around the connectors 172
generally at
outer surfaces of the connectors 172. The inner base member 176 further has an
engagement
surface 182 that abuts and engages an engagement surface 183 defined by the
outer base
member 175. As further shown in FIG. 84, with such configuration, a tortuous
path
represented by the phantom line L, is defined. Such tortuous path L minimizes
the chances
for moisture ingress. For example, a user may run through water puddles during
use
potentially exposing the port 14 and module 22 to moisture. In an exemplary
embodiment,
the connectors 172 are considered to be sealed to 5 ATM. A bonding material
(e.g. adhesive)
may be utilized between the module carrier 173 and the inner base member 176
proximate
the tortuous path L, such as at one or both points P in FIG. 84.
[0095] It is understood that the module 22 is received in the port 14. A
front end of the
module 22 is inserted through the central aperture 153 and into the first
section 144. The
module 22 is dimensioned to generally correspond in size to the first section
144 and in an
interference fit. In such configuration, the interface 23 on the module 22 is
operably engaged
with the interface 20 on the port 14 wherein the respective contacts of the
interfaces 20, 23
are in surface-to-surface contact. Thus, the construction is such that the
interface 23 of the
module 22 is forced against the interface 20 of the port 14. The module 22 may
have a recess
184 on a rear surface that receives the projection 151 of the housing 24 to
assist in retaining
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the module 22 in the port 14 through a snap connection. A user can easily
remove the
module 22 from the port by accessing the module 22 with the assistance of the
finger recess
29A. Thus, the modules 22 can easily be inserted into the port 14 and removed
from the port
14 when necessary such as for charging or transferring data, or when replacing
one type of
module 22 for one application with a different type of module for a different
application, or
replacing a power drained module 22 with a freshly charged module 22.
[0096] As shown in FIGS. 85-90, the module 22 is provided with a light
assembly 185 to
provide lighted indicia to a user. The light assembly 185 is operably
connected to the printed
circuit board 180. The light assembly 185 generally includes a light member
186 and a light
guide 187. The light member 186 is an LED light member in an exemplary
embodiment
although other light members can be used. The light member 186 has an arcuate
section 188
and is configured to project light in a first direction such as shown by the
arrow Al, which
may be a horizontal direction in an exemplary embodiment. The light member 186
may be
considered to be a side-firing LED. The light guide 187 has a first section
189 defining a first
passageway 190 configured in a first direction. The first section 189 has a
recessed area that
generally corresponds to and receives the arcuate section 188 of the light
member 186 to
capture as much light from the light member 186 as possible. Thus, the first
section 189 is in
confronting relation to the arcuate section 188 of the light member 186 and
partially encircles
the light member 186. As shown in the figures, the light guide 187 has a
geometry that
assists in spreading the light to a larger area, thus spreading the light out
along an arc. The
light guide 187 further has a second section 191defining a second passageway
192 configured
in a second direction. The second passageway 192 extends upwards and at an
angle and is
thus different from the first direction. In one exemplary embodiment, the
second section 191
is inclined at approximately a 45 degree angle which was determined to enhance
reflection of
the light. The second passageway 192 has a distal end that is positioned
proximate the
aperture 181 in the inner top member 179. The light guide 187 may be treated
with a
dispersant agent such as by adding the agent to the resin prior to injection
molding the light
guide. Because the light member 186 and light guide 187 are configured in
confronting
relation, the components achieve a minimized footprint, which is helpful due
to the limited
area defined in the module 22. In operation, the light member 186 is activated
as desired via
the printed circuit board 180. Light is projected in the direction shown by
the arrow Al.
Light is also projected in an arcuate configuration based on the shape of the
light guide 187.
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The light is projected in these directions into the first passageway 190. The
light guide 187
directs the light into the second passageway 192 in the direction of arrow A2
upwards. As
the light is initially projected from the side firing LED, the light
transitions from the direction
Al to an inclined direction towards the second passageway 192. Light then
passes through
the aperture 181 in the direction A2 and shines through outer top member 178.
The geometry
of the light guide 187 is tailored to evenly disperse light in a very short
path-length as shown.
The dispersant agent used with the light guide 187 assists in diffusing light
more evenly, thus
minimizing concentrations of light from the light member 186. Because of the
short path-
length involved, the LED light member 186 could project light that had more
focused
brightness in certain areas. With the present design, light is more evenly
spread and reflected
where there is a limited gradient of light across the aperture 181. The outer
top member 178
positioned over the aperture 181 is structured in thickness and colorant
loading of the
material to provide a desired translucency. Thus, as can be appreciated from
FIGS. 90 and
91, when the light member 186 is not illuminated, a user cannot detect that an
LED exists in
the module 22, thus providing a blank or "dead-front" appearance. Once the
light member
186 is activated, light is directed along the arrow Al and upwards along the
arrow A2, and
through the aperture 181 and outer top member 178 as shown by the designation
LT in FIG.
91. With the geometry and treatment of the light guide 187 and top members,
light is
reflected in a more enhanced manner providing an evenly dispersed light across
the entire
area of the light shining through the top member. Additional structures could
also be added
to reflect the light in a more enhanced manner. For example, the light guide
187 could be
provided with a surface texture to enhance light reflection. The inclined wall
of the light
guide 187 or other surfaces could be painted or have a sticker applied thereon
to achieve
desired changes in light reflection. It is understood that the light member
186 may project
light in multiple colors. The light member 186 provides indicia for indicating
various
parameters including battery life of the module 22.
[0097] The constructions of the port 14 and module 22 described herein
provide a snug
fit. The constructions provide a water tight configuration and resist moisture
ingress. These
properties are achieved while maintaining an operable connection between the
port 14 and
module 22. The fingers 158 on the interface assembly also provide a robust
connection with
the extension 21 of the insert member 37 as engagement locations between the
fingers and
extension are maximized. The filler material 159 is selected to have a desired
hardness to
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provide sufficient flexibility and anti-corrosion properties. In one exemplary
embodiment,
the filler material 159 may have a shore durometer on the type A scale of 30
or lower. The
filler material 159 provides protection around the connection between the
extension 21 and
the interface assembly 156. The receiver/post connections of the housing and
insert member
37 further provides stress relief to the insert member 37 to minimize chances
that the insert
member 37 could tear during use.
[0098] FIGS. 91-94 disclose additional features relating to a ground plan
extender
associated with the module 22. In particular, further aspects relate to
maximizing the surface
area of a layer of a PCB of one or more electronic devices, such as the module
22. Certain
aspects relate to increasing the surface area of a ground plane layer of a
PCB. FIG. 91 shows
a perspective top view of example PCB 1002, which may comprise on or more
components
in electric communication, including but not limited to processors,
capacitors, diodes,
resistors, and/or combinations thereof. PCB 1002 is shown to be planar across
a horizontal
axis ("x" axis), however, those skilled in the art will appreciate that PCB
1002 (or a plurality
of individual PCBs in operative communication) may be configured to form a non-
planar
structure. PCB 1002 further comprises a ground plane layer (see 1004) formed
of conductive
material, such as for example, copper. As shown in FIG. 91, the visible
portion of ground
plane layer 1004 is positioned around a periphery of PCB 1002, however,
portions of layer
1004 may be disposed and/or connected to other portions of PCB 1002.
[0099] In certain embodiments, at least one component of PCB 1002 may be
configurable
to be in operatively communication with a portable power supply, such as for
example, a
battery (not shown in FIGS. 91-93 but shown in FIG. 94). PCB 1002 may be
configured for
placement within a portable device having limited dimensions for batteries or
other forms of
portable power supplies. Due to the aforementioned dimensional restrictions of
portable
devices, batteries are often small, and such may have limited service time
between charges
and/or limited rates of discharge. In accordance with one embodiment, PCB 1002
may
comprise a space, such as battery space 1006. As shown in FIG. 91, battery
space 1006
comprises area along the x and z plane of PCB 1002 to permit placement of a
power source
adjacent to PCB 1002. PCB 1002 may be manufactured to dimensions creating
battery space
1002 or may be configured to be altered (such as through snap regions and/or
areas of
alternating thickness) to form one or more battery spaces. In this regard,
although the
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illustrative space is a battery space, those skilled in the art will
appreciate that this disclosure
is not limited to only those areas and/or spaces configured for housing or
positioning a
battery.
[00100] Although battery space 1006 of PCB 1002 is shown as a slot
configuration
flanked on three sides by portions of PCB 1002, those skilled in the art will
readily appreciate
that the shape, size and/or configuration of PCB 1002 is merely illustrative
and other shapes
are within the scope of this disclosure. The exact shape and size of battery
space 1006 may
be dictated by its intended use and is not limited by this disclosure. The
only requirement,
therefore, of battery space 1006 is the inclusion of area along the horizontal
plane (e.g., along
the x-axis) of PCB 1002 to permit placement of a power source along the same
plane and
adjacent to PCB 1002. As shown in FIG. 94, which shows a side view of PCB
1002, a
battery, such as battery 1008, may be positioned along the horizontal plane (x-
axis) of the
PCB 1002. Because battery 1008 occupies area within battery space 1006, the
surface area of
the PCB 1002 is minimized as compared with a PCB not having a space, such as
battery
space 1008, but instead includes a greater area of the ground plane layer 1004
located in the
same spot.
[00101] In accordance with certain embodiments, a ground plane extender (see,
e.g., 1010)
may be electronically connected to the ground plane layer 1004 of the PCB
1002. FIG. 92
shows an example ground plane extender 1010 in accordance with one embodiment.
Ground
plane extender 1010 may be formed of any material that effectively increases
the surface area
of the ground plane layer 1004. In one embodiment, the ground plane extender
may
comprise copper and/or aluminum, however, in further embodiments any
conductive material
may be utilized for at least a portion of ground plane extender 1010. One or
more connectors
1012 may be utilized to allow contact (and/or alignment) between extender 1010
and ground
plane layer 1004, either by conductive adhesives, soldering, pass through
soldering, welding,
snapping in, and combinations thereof. As best shown in FIG. 92, extender 1010
may be
placed adjacent to one side of the battery 1008 (e.g., the top), and comprise
a portion such as
a top region (e.g., 1014) that is substantially parallel to, and thus planar
with, PCB 1002
along the horizontal (x) axis. For example, extender 1010 may comprise a
vertical ridge
1016 that operatively connects to and extends from PCB 1002 to top region
1016. Top
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region 1016 may comprise one or more apertures 1018 that may permit heat
exchange from
the surrounding components, including battery 1008.
[00102] As seen in FIG. 94, extender 1010 is shown adjacent to a first side
(e.g., top side)
of battery 1008 and electronically connected with PCB 1002 and an antenna 1020
is
positioned adjacent to an opposing side (e.g. the bottom) of battery 1008. In
the example
embodiment of FIG. 94, the ground plane extender 1010 and antenna 1020 are
also in parallel
configuration with PCB 1002 and each other. Thus, in at least one embodiment,
a portable
device may comprise three layers ¨ a first layer comprising a ground plane
extender, such as
extender 1010, a second layer comprising a battery positioned such that at
least a portion of
the battery is along the same plane as a PCB operatively connected to the
ground plane
extender, and a third layer comprising an antenna, such as antenna, such as
antenna 1020. In
the illustrative embodiment, the layers are vertically arranged; however,
other arrangements
are within the scope of this disclosure. In this regard, there is no
requirement that each layer
be in direct physical contact with the adjacent surface of an adjacent layer,
unless otherwise
stated. For example, there is no requirement that antenna 1020 be in direct
physical contact
with the adjacent surface of battery 1008.
[00103] FIG. 6 shows a schematic diagram of an example electronic module 22
including
data transmission/reception capabilities through a data transmission/reception
system 107,
which may be used in accordance with at least some examples of this invention.
While the
example structures of FIG. 6 illustrate the data transmission/reception system
(TX-RX) 107
as integrated into the electronic module structure 22, those skilled in the
art will appreciate
that a separate component may be included as part of a footwear structure 100
or other
structure for data transmission/reception purposes and/or that the data
transmission/reception
system 107 need not be entirely contained in a single housing or a single
package in all
examples of the invention. Rather, if desired, various components or elements
of the data
transmission/reception system 107 may be separate from one another, in
different housings,
on different boards, and/or separately engaged with the article of footwear
100 or other
device in a variety of different manners without departing from this
invention. Various
examples of different potential mounting structures are described in more
detail below.
[00104] In the example of FIG. 6, the electronic component 22 may include a
data
transmission/reception element 107 for transmitting data to and/or receiving
data from one or
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more remote systems. In one embodiment, the transmission/reception element 107
is
configured for communication through the port 14, such as by the contacted or
contactless
interfaces described above. In the embodiment shown in FIG. 6, the module 22
includes an
interface 23 configured for connection to the port 14 and/or sensors 16. In
the module 22
illustrated in FIG. 6, the interface 23 has contacts that are complementary
with the terminals
11 of the interface 20 of the port 14, to connect with the port 14. In other
embodiments, as
described above, the port 14 and the module 22 may contain different types of
interfaces 20,
23, which may be contacted or wireless. It is understood that in some
embodiments, the
module 22 may interface with the port 14 and/or sensors 16 through the TX-RX
element 107.
Accordingly, in one embodiment, the module 22 may be external to the footwear
100, and the
port 14 may comprise a wireless transmitter interface for communication with
the module 22.
The electronic component 22 of this example further includes a processing
system 202 (e.g.,
one or more microprocessors), a memory system 204, and a power supply 206
(e.g., a battery
or other power source). In one embodiment, the power supply 206 may be
configured for
inductive charging, such as by including a coil or other inductive member. In
this
configuration, the module 22 may be charged by placing the article of footwear
100 on an
inductive pad or other inductive charger, allowing charging without removal of
the module
22 from the port 14. In another embodiment, the power supply 206 may
additionally or
alternately be configured for charging using energy-harvesting technology, and
may include a
device for energy harvesting, such as a charger that charges the power supply
206 through
absorption of kinetic energy due to movement of the user.
[00105] Connection to the one or more sensors can be accomplished as shown in
FIG. 6,
but additional sensors (not shown) may be provided to sense or provide data or
information
relating to a wide variety of different types of parameters, such as physical
or physiological
data associated with use of the article of footwear 100 or the user, including
pedometer type
speed and/or distance information, other speed and/or distance data sensor
information,
temperature, altitude, barometric pressure, humidity, GPS data, accelerometer
output or data,
heart rate, pulse rate, blood pressure, body temperature, EKG data, EEG data,
data regarding
angular orientation and changes in angular orientation (such as a gyroscope-
based sensor),
etc., and this data may be stored in memory 204 and/or made available, for
example, for
transmission by the transmission/reception system 107 to some remote location
or system.
The additional sensor(s), if present, may also include an accelerometer (e.g.,
for sensing
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direction changes during steps, such as for pedometer type speed and/or
distance information,
for sensing jump height, etc.). In one embodiment, the module 22 may include
an additional
sensor 208, such as an accelerometer, and the data from the sensors 16 may be
integrated
with the data from the accelerometer 208, such as by the module 22 or the
external device
110.
[00106] As additional examples, electronic modules, systems, and methods of
the various
types described above may be used for providing automatic impact attenuation
control for
articles of footwear. Such systems and methods may operate, for example, like
those
described in U.S. Pat. No. 6,430,843, U.S. Patent Application Publication No.
2003/0009913,
and U.S. Patent Application Publication No. 2004/0177531, which describe
systems and
methods for actively and/or dynamically controlling the impact attenuation
characteristics of
articles of footwear. When used for providing speed and/or distance type
information, sensing
units, algorithms, and/or systems of the types described in U.S. Pat. Nos.
5,724,265, 5,955,667,
6,018,705, 6,052,654, 6,876,947 and 6,882,955 may be used. Additional
embodiments of sensors
and sensor systems, as well as articles of footwear and sole structures and
members utilizing the
same, are described in U.S. Patent Application Publications Nos. 2010/0063778
and
2010/0063779.
[00107] The electronic module 22 can also include an activation system (not
shown). The
activation system or portions thereof may be engaged with the module 22 or
with the article
of footwear 100 (or other device) together with or separate from other
portions of the
electronic module 22. The activation system may be used for selectively
activating the
electronic module 22 and/or at least some functions of the electronic module
22 (e.g., data
transmission/reception functions, etc.). A wide variety of different
activation systems may be
used without departing from this invention, and a variety of such systems will
be described in
more detail below with respect to various included figures. In one example,
the sensor
system 12 may be activated and/or deactivated by activating the sensors 16 in
a specific
pattern, such as consecutive or alternating toe/heel taps. In another example,
the sensor
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system 12 may be activated by a button or switch, which may be located on the
module 22,
on the shoe 100, or on an external device in communication with the sensor
system 12, as
well as other locations. In any of these embodiments, the sensor system 12 may
contain a
"sleep" mode, which can deactivate the system 12 after a set period of
inactivity. In an
alternate embodiment, the sensor system 12 may operate as a low-power device
that does not
activate or deactivate.
[00108] The module 22 may further be configured for communication with an
external
device 110, which may be an external computer or computer system, mobile
device, gaming
system, or other type of electronic device, as shown in FIG. 23. The exemplary
external
device 110 shown in FIG. 23 includes a processor 302, a memory 304, a power
supply 306, a
display 308, a user input 310, and a data transmission/reception system 108.
The
transmission/reception system 108 is configured for communication with the
module 22 via
the transmission/reception system 107 of the module 22, through any type of
known
electronic communication, including the contacted and contactless
communication methods
described above and elsewhere herein. It is understood that the module 22
and/or the port 14
can be configured for communication with a plurality of external devices,
including a wide
variety of different types and configurations of electronic devices, and also
including
intermediate devices that function to pass information on to another external
device and may
or may not further process such data. Additionally, the transmission/reception
system 107 of
the module 22 may be configured for a plurality of different types of
electronic
communication. It is further understood that the shoe 100 may include a
separate power
source to operate the sensors 16 if necessary, such as a battery,
piezoelectric, solar power
supplies, or others. In the embodiment of FIGS. 3-22B, the sensors 16 receive
power through
connection to the module 22.
[00109] As described below, such sensor assemblies can be customized for use
with
specific software for the electronic module 22 and/or the external device 110.
A third party
may provide such software along with a sole insert having a customized sensor
assembly, as a
package. The module 22 and/or the overall sensor system 12 may cooperate with
one or
more algorithms for analysis of the data obtained from the sensors 16,
including algorithms
stored on and/or executed by the module, the external device 110, or another
component.
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[00110] In operation, the sensors 16 gather data according to their function
and design, and
transmit the data to the port 14. The port 14 then allows the electronic
module 22 to interface
with the sensors 16 and collect the data for later use and/or processing. In
one embodiment,
the data is collected, stored, and transmitted in a universally readable
format, so the data is
able to be accessed and/or downloaded by a plurality of users, with a variety
of different
applications, for use in a variety of different purposes. In one example, the
data is collected,
stored, and transmitted in XML format. In one embodiment, the module 22
detects pressure
changes in the sensors 16 utilizing the circuit 10 as shown in FIG. 20, by
measuring the
voltage drop at the measurement terminal 104b, which is reflective of the
changes in
resistance of the particular sensor 16 that is currently switched. FIG. 27
illustrates one
example of a pressure ¨ resistance curve for a sensor 16, with broken lines
illustrating
potential shifts of the curve due to factors such as bending of the insert 37.
The module 22
may have an activation resistance RA, which is the detected resistance
necessary for the
module 22 to register the pressure on the sensor. The corresponding pressure
to produce such
resistance is known as the activation pressure PA. The activation resistance
RA may be
selected to correspond to a specific activation pressure PA at which it is
desired for the
module 22 to register data. In one embodiment, the activation pressure PA may
be about 0.15
bar, about 0.2 bar, or about 0.25 bar, and the corresponding activation
resistance RA may be
about 1001d2. Additionally, in one embodiment, the highest sensitivity range
may be from
150-1500 mbar. In one embodiment, the sensor system 12 constructed as shown in
FIGS. 3-
22B can detect pressures in the range of 0.1-7.0 bar (or about 0.1-7.0 atm),
and in another
embodiment, the sensor system 12 may detect pressures over this range with
high sensitivity.
[00111] In different embodiments, the sensor system 12 may be configured to
collect
different types of data. In one embodiment (described above), the sensor(s) 16
can collect
data regarding the number, sequence, and/or frequency of compressions. For
example, the
system 12 can record the number or frequency of steps, jumps, cuts, kicks, or
other
compressive forces incurred while wearing the footwear 100, as well as other
parameters,
such as contact time and flight time. Both quantitative sensors and binary
on/off type sensors
can gather this data. In another example, the system can record the sequence
of compressive
forces incurred by the footwear, which can be used for purposes such as
determining foot
pronation or supination, weight transfer, foot strike patterns, or other such
applications. In
another embodiment (also described above), the sensor(s) 16 are able to
quantitatively
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measure the compressive forces on the adjacent portions of the shoe 100, and
the data
consequently can include quantitative compressive force and/or impact
measurement.
Relative differences in the forces on different portions of the shoe 100 can
be utilized in
determining weight distribution and "center of pressure" of the shoe 100. The
weight
distribution and/or center of pressure can be calculated independently for one
or both shoes
100, or can be calculated over both shoes together, such as to find a center
of pressure or
center of weight distribution for a person's entire body. In further
embodiments, the
sensor(s) 16 may be able to measure rates of changes in compressive force,
contact time,
flight time or time between impacts (such as for jumping or running), and/or
other
temporally-dependent parameters. It is understood that, in any embodiment, the
sensors 16
may require a certain threshold force or impact before registering the
force/impact, as
described above.
[00112] As described above, the data is provided through the universal port 14
to the
module 22 in a universally readable format, so that the number of
applications, users, and
programs that can use the data is nearly unlimited. Thus, the port 14 and
module 22 are
configured and/or programmed as desired by a user, and the port 14 and module
22 receive
input data from the sensor system 12, which data can be used in any manner
desired for
different applications. The module 22 may be able to recognize whether the
data received is
related to a left or right shoe, such as through the use of the unique
identification chip 92 as
described herein. The module 22 may process the data differently according to
the
recognition of L/R shoe, and may also transmit the data to the external device
110 with an
identification of whether the data is from a L/R shoe. The external device 110
may likewise
process or otherwise handle the data differently based on the identification
of L/R shoe as
well. In one example, the connections of the sensors 16 to the terminals 11
and the interface
20 may be different between the left and right inserts 37, as shown in FIG. 12
and discussed
above. The data from the left insert 37 may be interpreted differently from
the data from the
right insert 37 in accordance with this arrangement. The module 22 and/or the
electronic
device 110 may perform similar actions with respect to other identifying
information
contained on the unique identification chip 92. In many applications, the data
is further
processed by the module 22 and/or the external device 110 prior to use. In
configurations
where the external device 110 further processes the data, the module 22 may
transmit the data
to the external device 110. This transmitted data may be transmitted in the
same universally-
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readable format, or may be transmitted in another format, and the module 22
may be
configured to change the format of the data. Additionally, the module 22 can
be configured
and/or programmed to gather, utilize, and/or process data from the sensors 16
for one or more
specific applications. In one embodiment, the module 22 is configured for
gathering,
utilizing, and/or processing data for use in a plurality of applications.
Examples of such uses
and applications are given below. As used herein, the term "application"
refers generally to a
particular use, and does not necessarily refer to use in a computer program
application, as that
term is used in the computer arts. Nevertheless, a particular application may
be embodied
wholly or partially in a computer program application.
[00113] Further, in one embodiment, the module 22 can be removed from the
footwear
100 and replaced with a second module 22 configured for operating differently
than the first
module 22. For example, the replacement is accomplished by lifting the foot
contacting
member 133, disconnecting the first module 22 from the port 14 and removing
the first
module 22 from the housing 24, then inserting the second module 22 into the
housing 24 and
connecting the second module 22 to the port 14, and finally placing the foot
contacting
member 133 back into position. The second module 22 may be programmed and/or
configured differently than the first module 22. In one embodiment, the first
module 22 may
be configured for use in one or more specific applications, and the second
module 22 may be
configured for use in one or more different applications. For example, the
first module 22
may be configured for use in one or more gaming applications and the second
module 22 may
be configured for use in one or more athletic performance monitoring
applications.
Additionally, the modules 22 may be configured for use in different
applications of the same
type. For example, the first module 22 may be configured for use in one game
or athletic
performance monitoring application, and the second module 22 may be configured
for use in
a different game or athletic performance monitoring application. As another
example, the
modules 22 may be configured for different uses within the same game or
performance
monitoring application. In another embodiment, the first module 22 may be
configured to
gather one type of data, and the second module 22 may be configured to gather
a different
type of data. Examples of such types of data are described herein, including
quantitative
force and/or pressure measurement, relative force and/or pressure measurement
(i.e. sensors
16 relative to each other), weight shifting/transfer, impact sequences (such
as for foot strike
patterns) rate of force and/or pressure change, etc. In a further embodiment,
the first module
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22 may be configured to utilize or process data from the sensors 16 in a
different manner than
the second module 22. For example, the modules 22 may be configured to only
gather, store,
and/or communicate data, or the modules 22 may be configured to further
process the data in
some manner, such as organizing the data, changing the form of the data,
performing
calculations using the data, etc. In yet another embodiment, the modules 22
may be
configured to communicate differently, such as having different communication
interfaces or
being configured to communicate with different external devices 110. The
modules 22 may
function differently in other aspects as well, including both structural and
functional aspects,
such as using different power sources or including additional or different
hardware
components, such as additional sensors as described above (e.g. GPS,
accelerometer, etc.).
[00114] One use contemplated for the data collected by the system 12 is in
measuring
weight transfer, which is important for many athletic activities, such as a
golf swing, a
baseball/softball swing, a hockey swing (ice hockey or field hockey), a tennis
swing,
throwing/pitching a ball, etc. The pressure data collected by the system 12
can give valuable
feedback regarding balance and stability for use in improving technique in any
applicable
athletic field. It is understood that more or less expensive and complex
sensor systems 12
may be designed, based on the intended use of the data collected thereby.
[00115] The data collected by the system 12 can be used in measurement of a
variety of
other athletic performance characteristics. The data can be used to measure
the degree and/or
speed of foot pronation/supination, foot strike patterns, balance, and other
such parameters,
which can be used to improve technique in running/jogging or other athletic
activities. With
regard to pronation/supination, analysis of the data can also be used as a
predictor of
pronation/supination. Speed and distance monitoring can be performed, which
may include
pedometer-based measurements, such as contact measurement or loft time
measurement.
Jump height can also be measured, such as by using contact or loft time
measurement.
Lateral cutting force can be measured, including differential forces applied
to different parts
of the shoe 100 during cutting. The sensors 16 can also be positioned to
measure shearing
forces, such as a foot slipping laterally within the shoe 100. As one example,
additional
sensors may be incorporated into the sides of the upper 120 of the shoe 100 to
sense forces
against the sides.
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[00116] The data, or the measurements derived therefrom, may be useful for
athletic
training purposes, including improving speed, power, quickness, consistency,
technique, etc.
The port 14, module 22, and/or external device 110 can be configured to give
the user active,
real-time feedback. In one example, the port 14 and/or module 22 can be placed
in
communication with a computer, mobile device, etc., in order to convey results
in real time.
In another example, one or more vibration elements may be included in the shoe
100, which
can give a user feedback by vibrating a portion of the shoe to help control
motion, such as the
features disclosed in U.S. Patent No. 6,978,684. Additionally,
the data can be used to compare athletic movements,
such as comparing a movement with a user's past movements to show consistency,
improvement, or the lack thereof, or comparing a user's movement with the same
movement
of another, such as a professional golfer's swing. Further, the system 12 may
be used to
record biomechanical data for a "signature" athletic movement of an athlete.
This data could
be provided to others for use in duplicating or simulating the movement, such
as for use in
gaming applications or in a shadow application that overlays a movement over a
user's
similar movement.
[001171 The system 12 can also be configured for "all day activity" tracking,
to record the
various activities a user engages in over the course of a day. The system 12
may include a
special algorithm for this purpose, such as in the module 22, the external
device 110, and/or
the sensors 16.
[00118] The system 12 may also be used for control applications, rather than
data
collection and processing applications. In other words, the system 12 could be
incorporated
into footwear, or another article that encounters bodily contact, for use in
controlling an
external device 110, such as a computer, television, video game, etc., based
on movements by
the user detected by the sensors 16. In effect, the footwear with the
incorporated sensors 16
and leads 18 extending to a universal port 14 allows the footwear to act as an
input system,
and the electronic module 22 can be configured, programmed, and adapted to
accept the input
from the sensors 16 and use this input data in any desired manner, e.g., as a
control input for
a remote system. For example, a shoe with sensor controls could be used as a
control or input
device for a computer, or for a program being executed by the computer,
similarly to a
mouse, where certain foot movements, gestures, etc. (e.g., a foot tap, double
foot tap, heel
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tap, double heel tap, side-to-side foot movement, foot-point, foot-flex, etc.)
can control a pre-
designated operation on a computer (e.g., page down, page up, undo, copy, cut,
paste, save,
close, etc.). Software can be provided to assign foot gestures to different
computer function
controls for this purpose. It is contemplated that an operating system could
be configured to
receive and recognize control input from the sensor system 12. Televisions or
other external
electronic devices can be controlled in this manner. Footwear 100
incorporating the system
12 can also be used in gaming applications and game programs, similarly to the
Nintendo Wii
controller, where specific movements can be assigned certain functions and/or
can be used to
produce a virtual representation of the user's motion on a display screen. As
one example,
center of pressure data and other weight distribution data can be used in
gaming applications,
which may involve virtual representations of balancing, weight shifting, and
other
performance activities. The system 12 can be used as an exclusive controller
for a game or
other computer system, or as a complementary controller. Examples of
configurations and
methods of using sensor systems for articles of footwear as controls for
external devices and
foot gestures for such controls are shown and described in U.S. Provisional
Application No.
61/138,048.
100119] Additionally, the system 12 may be configured to communicate directly
with the
external device 110 and/or with a controller for the external device. As
described above,
FIG. 6 illustrates one embodiment for communication between the electronic
module 22 and
the external device. In another embodiment, shown in FIG. 23, the system 12
can be
configured for communication with an external gaming device 110A. The external
gaming
device 110A contains similar components to the exemplary external device 110
shown in
FIG. 6. The external gaming device 110A also includes at least one game media
307
containing a game program (e.g. a cartridge, CD, DVD, Blu-Ray, or other
storage device),
and at least one remote controller 305 configured to communicate by wired
and/or wireless
connection through the transmitting/receiving element 108. In the embodiment
shown, the
controller 305 complements the user input 310, however in one embodiment, the
controller -
305 may function as the sole user input. In this embodiment, the system 12 is
provided with
an accessory device 303, such as a wireless transmitter/receiver with a USB
plug-in, that is
configured to be connected to the external device 110 and/or the controller
305 to enable
communication with the module 22. In one embodiment, the accessory device 303
may be
configured to be connected to one or more additional controllers and/or
external devices, of
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the same and/or different type than the controller 305 and the external device
110. It is
understood that if the system 12 includes other types of sensors described
above (e.g., an
accelerometer), such additional sensors can also be incorporated into
controlling a game or
other program on an external device 110.
[00120] An external device 110, such as a computer/gaming system, can be
provided with
other types of software to interact with the system 12. For example, a gaming
program may
be configured to alter the attributes of an in-game character based on a
user's real-life
activities, which can encourage exercise or greater activity by the user. In
another example, a
program may be configured to display an avatar of the user that acts in
relation or proportion
to the user activity collected by the sensing system of the shoe. In such a
configuration, the
avatar may appear excited, energetic, etc., if the user has been active, and
the avatar may
appear sleepy, lazy, etc., if the user has been inactive. The sensor system 12
could also be
configured for more elaborate sensing to record data describing a "signature
move" of an
athlete, which could then be utilized for various purposes, such as in a
gaming system or
modeling system.
[00121] A single article of footwear 100 containing the sensor system 12 as
described
herein can be used alone or in combination with a second article of footwear
100' having its
own sensor system 12', such as a pair of shoes 100, 100' as illustrated in
FIGS. 24-26. The
sensor system 12' of the second shoe 100' generally contains one or more
sensors 16'
connected by sensor leads 18' to a port 14' in communication with an
electronic module 22'.
The second sensor system 12' of the second shoe 100' shown in FIGS. 24-26 has
the same
configuration as the sensor system 12 of the first shoe 100. However, in
another
embodiment, the shoes 100, 100' may have sensor systems 12, 12' having
different
configurations. The two shoes 100, 100' are both configured for communication
with the
external device 110, and in the embodiment illustrated, each of the shoes 100,
100' has an
electronic module 22, 22' configured for communication with the external
device 110. In
another embodiment, both shoes 100, 100' may have ports 14, 14' configured for
communication with the same electronic module 22. In this embodiment, at least
one shoe
100, 100' may be configured for wireless communication with the module 22.
FIGS. 24-26
illustrate various modes for communication between the modules 22, 22'.
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[00122] FIG. 24 illustrates a "mesh" communication mode, where the modules 22,
22' are
configured for communicating with each other, and are also configured for
independent
communication with the external device 110. FIG. 25 illustrates a "daisy
chain"
communication mode, where one module 22' communicates with the external device
110
through the other module 22. In other words, the second module 22' is
configured to
communicate signals (which may include data) to the first module 22, and the
first module 22
is configured to communicate signals from both modules 22, 22' to the external
device 110.
Likewise, the external device communicates with the second module 22' through
the first
module 22, by sending signals to the first module 22, which communicates the
signals to the
second module 22'. In one embodiment, the modules 22, 22' can also communicate
with
each other for purposes other than transmitting signals to and from the
external device 110.
FIG. 26 illustrates an "independent" communication mode, where each module 22,
22' is
configured for independent communication with the external device 110, and the
modules 22,
22' are not configured for communication with each other. In other
embodiments, the sensor
systems 12, 12' may be configured for communication with each other and/or
with the
external device 110 in another manner.
[00123] As will be appreciated by one of skill in the art upon reading the
present
disclosure, various aspects described herein may be embodied as a method, a
data processing
system, or a computer program product. Accordingly, those aspects may take the
form of an
entirely hardware embodiment, an entirely software embodiment or an embodiment
combining software and hardware aspects. Furthermore, such aspects may take
the form of a
computer program product stored by one or more tangible computer-readable
storage media
or storage devices having computer-readable program code, or instructions,
embodied in or
on the storage media. Any suitable tangible computer readable storage media
may be
utilized, including hard disks, CD-ROMs, optical storage devices, magnetic
storage devices,
and/or any combination thereof. In addition, various intangible signals
representing data or
events as described herein may be transferred between a source and a
destination in the form
of electromagnetic waves traveling through signal-conducting media such as
metal wires,
optical fibers, and/or wireless transmission media (e.g., air and/or space).
[00124] As described above, aspects of the present invention may be described
in the
general context of computer-executable instructions, such as program modules,
being
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executed by a computer and/or a processor thereof Generally, program modules
include
routines, programs, objects, components, data structures, etc. that perform
particular tasks or
implement particular abstract data types. Such a program module may be
contained in a
tangible, non-transitory computer-readable medium, as described above. Aspects
of the
present invention may also be practiced in distributed computing environments
where tasks
are performed by remote processing devices that are linked through a
communications
network. Program modules may be located in a memory, such as the memory 204 of
the
module 22 or memory 304 of the external device 110, or an external medium,
such as game
media 307, which may include both local and remote computer storage media
including
memory storage devices. It is understood that the module 22, the external
device 110, and/or
external media may include complementary program modules for use together,
such as in a
particular application. It is also understood that a single processor 202, 302
and single
memory 204, 304 are shown and described in the module 22 and the external
device 110 for
sake of simplicity, and that the processor 202, 302 and memory 204, 304 may
include a
plurality of processors and/or memories respectively, and may comprise a
system of
processors and/or memories.
[00125] The sensor system described herein can be utilized in a variety of
different
applications and configurations including general athletic performance
monitoring such as in
fitness training or sport specific activity such as basketball. It is
understood that additional
sensors can be positioned at other locations on the footwear. The sensors in
the sensor
system can also be configured to sense specific lateral movements and athletic
cutting
movements. As discussed herein, data collected by the sensor system can be
processed by
the associated algorithms either in the electronic module, the mobile device
or a remote site.
It is contemplated that such data processing can be used to advise users
regarding wear such
that the user is advised when a new pair of shoes is needed. Such data could
also be
processed and used to advise a user of a particular type of shoe design that
may be beneficial
for the particular user. Finally, the data can be processed to aid in the
custom design of
footwear. While the sensor system is shown in footwear, the system can be used
in other
types of apparel.
[00126] The various embodiments of the sensor system described herein, as well
as the
articles of footwear, foot contacting members, inserts, and other structures
incorporating the
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sensor system, provide benefits and advantages over existing technology. For
example, many
of the sensor embodiments described herein provide relatively low cost and
durable options
for sensor systems, so that a sensor system can be incorporated into articles
of footwear with
little added cost and good reliability. As a result, footwear can be
manufactured with integral
sensor systems regardless of whether the sensor systems are ultimately desired
to be used by
the consumer, without appreciably affecting price. Additionally, sole inserts
with customized
sensor systems can be inexpensively manufactured and distributed along with
software
designed to utilize the sensor systems, without appreciably affecting the cost
of the software.
As another example, the sensor system provides a wide range of functionality
for a wide
Variety of applications, including gaming, fitness, athletic training and
improvement, practical
controls for computers and other devices, and many others described herein and
recognizable
to those skilled in the art. In one embodiment, third-party software
developers can develop
software configured to run using input from the sensor systems, including
games and other
programs. The ability of the sensor system to provide data in a universally
readable format
greatly expands the range of third party software and other applications for
which the sensor
system can be used. Additionally, in one embodiment, the sensor system can
produce signals
and data that permit accurate detection of applied forces, which provides
greater utility and
versatility. As a further example, the various sole inserts containing sensor
systems,
including liners, insoles, and other elements, permit interchangeability and
customization of
the sensor system for different applications. Other advantages are
recognizable to those
skilled in the art.
[00127] Several alternative embodiments and examples have been described and
illustrated herein. A person of ordinary skill in the art would appreciate the
features of the
individual embodiments, and the possible combinations and variations of the
components. A
person of ordinary skill in the art would further appreciate that any of the
embodiments could
be provided in any combination with the other embodiments disclosed herein. It
is
understood that the invention may be embodied in other specific forms without
departing
from the scope thereof. The present examples and embodiments
therefore, are to be considered in all respects as illustrative and not
restrictive, and the
invention is not to be limited to the details given herein. The terms "first,"
"second," "top,"
"bottom," etc., as used herein, are intended for illustrative purposes only
and do not limit the
embodiments in any way. Additionally, the term "plurality," as used herein,
indicates any
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number greater than one, either disjunctively or conjunctively, as necessary,
up to an infinite
number. Further, "Providing" an article or apparatus, as used herein, refers
broadly to
making the article available or accessible for future actions to be performed
on the article,
and does not connote that the party providing the article has manufactured,
produced, or
supplied the article or that the party providing the article has ownership or
control of the
article. Accordingly, while specific embodiments have been illustrated and
described,
numerous modifications come to mind without significantly departing from the
scope of the
invention and the scope of protection is only limited by the scope of the
accompanying
Claims.
