Intelligent footwear systems (15-Dec-2009)

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation-in-part of U.S. patent application Ser. No. 11/047,550, filed on Jan. 31, 2005, which is a continuation-in-part of U.S. patent application Ser. No. 10/385,300, filed on Mar. 10, 2003 the entire disclosures of which are hereby incorporated herein by reference. This application also claims priority to U.S. Provisional Patent Application Ser. No. 60/557,902, filed on Mar. 30, 2004, the disclosure of which is hereby incorporated herein by reference in its entirety.

TECHNICAL FIELD

The invention generally relates to intelligent systems for articles of footwear. In particular, the invention relates to automatic, self-adjusting systems that modify a performance characteristic of the article of footwear.

BACKGROUND INFORMATION

Conventional athletic shoes include an upper and a sole. The material of the sole is usually chosen with a view towards optimizing a particular performance characteristic of the shoe, for example, stability or stiffness. Typically, the sole includes a midsole and an outsole, either of which can include a resilient material to protect a wearer's foot and leg. One drawback with conventional shoes is that performance characteristics, such as cushioning and stiffness, are not adjustable. The wearer must, therefore, select a specific shoe for a specific activity. For example, for activities requiring greater cushioning, such as running, the wearer must select one type of shoe and for activities requiring greater stiffness for support during lateral movement, such as basketball, the wearer must select a different type of shoe.

Some shoes have been designed to allow for adjustment in the degree of cushioning or stiffness provided by the sole. Many of these shoes employ a fluid bladder that can be inflated or deflated as desired. A disadvantage presented by these shoes is that one or more of the bladders can fail, rendering the cushioning system effectively useless. Moreover, many of the shoes employing fluid bladders do not allow for small-scale changes to the degree of cushioning provided by the sole. Often, the change to the degree of cushioning provided by the sole in pressurizing or depressurizing, or in partially pressurizing or partially depressurizing, a bladder will be larger than that desired by the wearer. In other words, bladders are typically not capable of fine adjustments.

A further disadvantage of many of the shoes designed to allow for adjustment in the degree of cushioning or stiffness provided by the sole is that they are only manually adjustable. Accordingly, in order to adjust such shoes the wearer is required to interrupt the specific activity in which he/she is engaged. With some shoes, the wearer may also be required to partially disassemble the shoe, re-assemble the shoe, and even exchange shoe parts. Moreover, the wearer, to his or her dissatisfaction, may be limited in the amount of adjustment that can be made.

Some shoes have been designed to automatically adjust the degree of cushioning or stiffness provided by the sole. These shoes measure the amount of force or pressure exerted on the sole by the wearer's foot when the wearer's foot strikes the ground. Through analysis and investigation, it has been discovered that the mere measurement of force or pressure alone, however, is too limited, as it provides no information relating to the performance of the shoe. For example, measuring force provides no indication as to whether the sole has either over-compressed or under-compressed for that particular wearer without prior investigation into the normal forces exerted by the wearer during the activity. If the sole is either over-compressed or under-compressed, the shoe is poorly matched to the wearer's activity and needs. In essence, the wearer's body has to adapt to the shoe. The biomechanical needs of the wearer are poorly met, if at all.

In sum, shoes that have been designed to allow for some adjustment in the degree of cushioning or stiffness provided by the sole still fall short of accommodating the wearer's needs. Specifically, they are not fully adjustable throughout the range of the biomechanical needs of the particular wearer or lack the ability to sense the true needs of the wearer. As a result, the wearer must still, in some way, adapt his or her body to the environment presented by the shoe.

There is, therefore, a need for a shoe that senses the biomechanical needs of the wearer, automatically adjusts a performance characteristic of the shoe to accommodate the biomechanical needs of the wearer, for example the degree of cushioning or stiffness provided by the sole, and avoids the drawbacks of bladder cushioning or manually adjustable shoes.

SUMMARY OF THE INVENTION

The invention is directed to intelligent systems for articles of footwear that adjust a feature of the footwear in response to the footwear's environment, without human interaction. In other words, the footwear is adaptive. For example, the intelligent system can continuously sense the biomechanical needs of the wearer and concomitantly modify the footwear to an optimal configuration. The intelligent system includes a sensing system, a control system, and an actuation system. Further, the intelligent system can sense the conditions of use of the article of footwear, understand under what condition the article of footwear is being used, and adapt the article of footwear accordingly.

The sensing system measures a performance characteristic of the article of footwear and sends a signal to the control system. The signal is representative of the measured performance characteristic. The control system processes the signal to determine if, for example, the performance characteristic deviates from an acceptable range or exceeds a predetermined threshold. The control system sends a signal to the actuation system relative to the deviation. The actuation system modifies a feature of the footwear in order to obtain an optimal performance characteristic.

In one aspect, the invention relates to an intelligent system for an article of footwear. The system includes a control system, a power source electrically coupled to the control system, an adjustable element, and a driver coupled to the adjustable element. The driver adjusts the adjustable element in response to a signal from the control system.

In another aspect, the invention relates to an article of footwear including an upper coupled to a sole and an intelligent system at least partially disposed in the sole. The system includes a control system, a power source electrically coupled to the control system, an adjustable element, and a driver coupled to the adjustable element. The driver adjusts the adjustable element in response to a signal from the control system.

In various embodiments of the foregoing aspects, the system modifies a performance characteristic of the article of footwear, such as compressibility, resiliency, compliancy, elasticity, damping, energy storage, cushioning, stability, comfort, velocity, acceleration, jerk, stiffness, or combinations thereof. In one embodiment, the adjustable element is adjusted by at least one of translation, rotation, reorientation, modification of a range of motion, or combinations thereof. The system may include a limiter for limiting a range of motion of the adjustable element. The control system includes a sensor and electrical circuitry. The sensor may be a pressure sensor, a force transducer, a hall effect sensor, a strain gauge, a piezoelectric element, a load cell, a proximity sensor, an optical sensor, an accelerometer, a hall element or sensor, a capacitance sensor, an inductance sensor, an ultrasonic transducer and receiver, a radio frequency emitter and receiver, a magneto-resistive element, or a giant magneto-resistive element. In various embodiments, the driver may be a worm drive, a lead screw, a rotary actuator, a linear actuator, a gear train, a linkage, a cable driving system, a latching mechanism, a piezo material based system, a shape memory material based system, a system using a magnetorheological fluid, a system using an inflatable bladder(s), or combinations thereof.

In still other embodiments, the adjustable element may be at least partially disposed in at least one of a forefoot portion, a midfoot portion, and a rearfoot portion of the article of footwear. In one embodiment, the article of footwear has a sole including an outsole and a midsole and the adjustable element is disposed at least partially in the midsole. In various embodiments, the adjustable element may be generally longitudinally disposed within the article of footwear, or the adjustable element may be generally laterally disposed within the article of footwear, or both. For example, the adjustable element may extend from a heel region to an arch region of the article of footwear or from an arch region to a forefoot region of the article of footwear or from a forefoot region to a heel region of the article of footwear. Furthermore, the adjustable element may be at least partially disposed in a lateral side, or a medial side, or both of the article of footwear.

In another aspect, the invention relates to a method of modifying a performance characteristic of an article of footwear during use. The method includes the steps of monitoring the performance characteristic of the article of footwear, generating a corrective driver signal, and adjusting an adjustable element based on the driver signal to modify the performance characteristic of the article of footwear. In one embodiment, the steps are repeated until a threshold value of the performance characteristic is obtained.

In various embodiments of the foregoing aspect, the generating step includes the substeps of comparing the monitored performance characteristic to a desired performance characteristic to generate a deviation and outputting a corrective driver signal magnitude based on the deviation. In one embodiment, the corrective driver signal has a predetermined magnitude. Further, the monitoring step may include the substeps of measuring a magnetic field of a magnet with a proximity sensor, wherein at least one of the magnet and the sensor are at least partially disposed within the sole and are vertically spaced apart in an unloaded state, and comparing the magnetic field measurement during compression to a threshold value. In one embodiment, the monitoring step involves taking multiple measurements of the magnetic field during compression and comparing an average magnetic field measurement to the threshold value.

In additional embodiments, the method may include the step of limiting a range of motion of the adjustable element with a limiter and the adjusting step may include adjusting the limiter a predetermined distance. The adjustment step may be performed when the article of footwear is in an unloaded state. In one embodiment, the adjustment step is terminated when a threshold value of the performance characteristic is reached.

In various embodiments of all of the foregoing aspects of the invention, the adjustable element may be an expansion element, a multiple density foam, a skeletal element, a multidensity plate, or combinations thereof. The adjustable element may exhibit an anisotropic property. In one embodiment, the adjustable element may be a generally elliptically-shaped expansion element. Further, the system may include a manual adjustment for altering or biasing the performance characteristic of the adjustable element, or an indicator, or both. The manual adjustment may also alter a threshold value of the performance characteristic. The indicator may be audible, visual, or both. For example, the indicator may be a series of electro-luminescent elements.

In another aspect, the invention relates to a system for measuring compression within an article of footwear. The system includes a sensor at least partially disposed within a sole of the article of footwear and a magnet generally aligned with and spaced from the sensor. The sensor may be a hall effect sensor, a proximity sensor, a hall element or sensor, a capacitance sensor, an inductance sensor, an ultrasonic transducer and receiver, a radio frequency emitter and receiver, a magneto-resistive element, or a giant magneto-resistive element. The system may include a processor. In one embodiment, the sensor measures a magnetic field generated by the magnet and the processor converts the magnetic field measurement into a distance measurement representing an amount of compression of the sole in correlation with respective time measurements. The processor may convert the distance measurements into a jerk value, a value representing acceleration, a value representing optimal compression, and/or a value representing a compression force.

In various embodiments of the foregoing aspect, the system further includes a driver coupled to the sensor and an adjustable element coupled to the driver. The system may include a limiter for limiting a range of motion of the adjustable element. In one embodiment, a performance characteristic of the article of footwear is modified in response to a signal from the sensor. In one embodiment, the signal corresponds to an amount of compression of the sole.

In another aspect, the invention relates to a method of providing comfort in an article of footwear. The method includes the steps of providing an adjustable article of footwear and determining a jerk value, a value representing acceleration, a value representing optimal compression, and/or a value representing a compression force. The method may further include the step of modifying a performance characteristic of the adjustable article of footwear based on the jerk value, the value representing acceleration, the value representing optimal compression, or the value representing a compression force.

In another aspect, the invention relates to a method for modifying a performance characteristic of an article of footwear during use. The method includes the steps of measuring a sensor signal from a sensor at least partially disposed within a sole of the article of footwear, and determining whether the sole has compressed. The method also includes, upon determining that the sole has compressed, the step of determining whether adjustment of the sole is required, and, upon determining that adjustment of the sole is required, the step of adjusting the sole.

In various embodiments of the foregoing aspect, the method further includes the steps of receiving a user input related to adjustment of the sole from a user of the article of footwear, adjusting a hardness setting for the sole in response to receiving the user input, and displaying the hardness setting for the sole by activating at least one electro-luminescent element, such as a light-emitting diode (LED) or an organic light emitting diode (OLED), disposed on the article of footwear. The method may also include the step of calculating at least one threshold of compression in response to receiving the user input. The at least one threshold of compression, which may be a lower threshold of compression and/or an upper threshold of compression, may be for use in determining whether adjustment of the sole is required.

In one embodiment, the step of measuring the sensor signal includes sampling the sensor signal a plurality of times. The step of measuring the sensor signal may also include calculating an average value for the sensor signal by averaging a subset of the plurality of samples of the sensor signal.

In another embodiment, the step of measuring the sensor signal is repeated at least once to obtain a plurality of measurements of the sensor signal. In one such embodiment, the step of determining whether the sole has compressed includes calculating a difference between an average of a plurality of previously obtained measurements of the sensor signal and the most recently obtained measurement of the sensor signal. The step of determining whether the sole has compressed may also include calculating this difference each time a new measurement of the sensor signal is obtained and/or determining whether a predetermined number of those calculated differences is greater than a predetermined constant.

In yet another embodiment, the step of measuring the sensor signal includes measuring compression in the sole. In one such embodiment, the step of determining whether adjustment of the sole is required includes determining the maximum amount of measured compression in the sole.

In still another embodiment, the step of determining whether adjustment of the sole is required includes determining whether there is a change in a surface condition on which the article of footwear is used. In one embodiment, the step of determining whether there is a change in the surface condition on which the article of footwear is used includes determining whether there is a change in a first parameter over time and substantially no change in a second parameter over time. In other embodiments, the step of determining whether there is a change in the surface condition on which the article of footwear is used includes determining whether there is a change in an absolute compression in the sole over time and substantially no change in a deviation of the compression in the sole over time, or alternatively, determining whether there is a change in the deviation of the compression in the sole over time and substantially no change in the absolute compression in the sole over time.

The surface condition on which the article of footwear is used may be determined to have changed from a hard ground surface to a soft ground surface. Alternatively, the surface condition may be determined to have changed from a soft ground surface to a hard ground surface. In one embodiment, the determination of whether there is a change in the surface condition on which the article of footwear is used is made after a wearer of the article of footwear has taken a plurality of steps.

In a further embodiment, the step of determining whether adjustment of the sole is required includes determining that the compression in the sole is less than a lower threshold of compression. In such a case, the step of adjusting the sole includes softening the sole. Alternatively, in another embodiment, the step of determining whether adjustment of the sole is required includes determining that the compression in the sole is greater than an upper threshold of compression. In this latter case, the step of adjusting the sole includes hardening the sole. In one embodiment, the adjustment of the sole is made after a wearer of the article of footwear has taken a plurality of steps.

Additionally, the step of adjusting the sole may include actuating a motor located within the sole. In one such embodiment, the method further includes the step of determining the status of the motor located within the sole. Determining the status of the motor may include sampling a battery voltage or using a potentiometer, an encoder, or any other suitable type of measuring device.

In another aspect, the invention relates to a controller for modifying a performance characteristic of an article of footwear during use. The controller includes a receiver configured to receive a first signal representing an output from a sensor at least partially disposed within a sole of the article of footwear, a determination module configured to determine whether the sole has compressed and to determine whether adjustment of the sole is required, and a transmitter configured to transmit a second signal for adjusting the sole.

In another aspect, the invention relates to an article of footwear that includes an upper coupled to a sole and a controller at least partially disposed within the sole. The controller includes means for receiving a first signal representing an output from a sensor at least partially disposed within the sole, means for determining whether the sole has compressed and for determining whether adjustment of the sole is required, and means for transmitting a second signal for adjusting the sole.

In another aspect, the invention relates to a method for modifying a performance characteristic of an article of footwear during use. The method includes the steps of measuring a sensor signal from a sensor at least partially disposed within a sole of the article of footwear, determining whether the article of footwear has experienced a peak condition, if so, determining whether adjustment of the article of footwear is required, and, if so, adjusting a performance characteristic of the article of footwear.

In various embodiments of the method, the peak condition is based on a change in state of the article of footwear as a result of an activity resulting in a compression criterion, such as a jump, a landing, a sprint, a turn, a cut, a push-off, and a stop. In some embodiments, the activity may cause an irregular profile. The change in state of the article can be represented by at least one of absolute compression, rate of compression, frequency of compression, change in rate of compression, uneven compression, velocity, acceleration, jerk, and combinations thereof. For example, if a wearer of an article of footwear embodying the invention experiences excessive pronation, the system senses uneven compression across the sole and can stiffen the sole, or portions thereof, as necessary to compensate therefor. Additionally, changes in the rate of compression may indicate that the wearer is changing pace from walking to sprinting, thereby warranting changing a performance characteristic of the shoe to compensate therefor. The method can further include the step of adjusting a threshold value for determining the peak condition. The method can include the step of evaluating when the peak condition is over and returning the threshold value to its previous setting. Various embodiments of the method can also include tracking a plurality of peak conditions experienced by the article of footwear and determining a new threshold value for determining whether the article of footwear has experienced a peak condition based on the plurality of peak conditions experienced. For example, the threshold setting for a particular user may be too low for the particular activity engaged, which can be determined by the system analyzing the plurality of peak conditions. The system can then adjust the threshold value or performance characteristic as necessary.

The method can further include the steps of monitoring a state of the article of footwear, determining if the article is inactive and, if so, enabling a sleep mode in the intelligent system. The step of monitoring the state of the article of footwear can include sampling the sensor signal at set intervals and, in one embodiment, determining whether the sensor signal has remained substantially constant for a set time period. The step of enabling a sleep mode in the intelligent system can include reducing power to at least one portion of the intelligent system. The intelligent system can be reactivated upon an indication of use of the article of footwear, such as a vibration, a force, acceleration, velocity, and an increase in temperature within the shoe or a change in electric or other field strength within the shoe (such as a change in capacitance). In addition, the method can include the steps of receiving a user input related to an adjustment of the performance characteristic through a user interface and adjusting an adjustable element at least partially disposed within the article of footwear in response to the user input. In one embodiment, the user interface can be a capacitive user interface, a button, a switch, a slider, a dial, or combinations thereof. The method can include providing an indication of a setting of the performance characteristic through an indicator, for example at least one electro-luminescent element disposed on the article of footwear.

In another aspect, the invention relates to an intelligent system for adjusting a performance characteristic of an article of footwear. The system includes a control system, a power source electrically coupled to the control system, an adjustable element, a driver coupled to the adjustable element for adjusting the adjustable element in response to a signal from the control system, and at least one user interface. The user interface can be a capacitive user interface, a button, a switch, a slider, a dial, or combinations thereof. A setting of the performance characteristic can be adjusted based on an input through the user interface.

In various embodiments, the driver includes a motor shaft and a sensor for determining an angular position or rotation counts of the motor shaft or number of shaft rotations. The sensor can be a magnetic sensor, any field sensor, a mechanical sensor, an optical sensor, or combinations thereof. The control system, power source, adjustable element, and driver can be arranged in a substantially horizontal orientation within a sole of the article of footwear. Such an arrangement can be used to reduce the overall height of the sole of the article of footwear.

In one embodiment, at least one of the control system, power source, adjustable element, and driver can be housed in a waterproof casing. In this embodiment, the waterproof casing can enable the intelligent system to perform when subjected to high levels of moisture. An assembly of the control system, the power source, the adjustable element, and the driver can also include a plurality of gaskets to render the assembly waterproof.

These and other objects, along with advantages and features of the present invention herein disclosed, will become apparent through reference to the following description, the accompanying drawings, and the claims. Furthermore, it is to be understood that the features of the various embodiments described herein are not mutually exclusive and can exist in various combinations and permutations.

BRIEF DESCRIPTION OF THE DRAWINGS

In the drawings, like reference characters generally refer to the same parts throughout the different views. Also, the drawings are not necessarily to scale, emphasis instead generally being placed upon illustrating the principles of the invention. In the following description, various embodiments of the present invention are described with reference to the following drawings, in which:

FIG. 1 is a partially exploded schematic perspective view of an article of footwear including an intelligent system in accordance with one embodiment of the invention;

FIG. 2A is an exploded schematic perspective view of a sole of the article of footwear of FIG. 1 in accordance with one embodiment of the invention;

FIG. 2B is an enlarged schematic side view of the intelligent system of FIG. 2A illustrating the operation of the adjustable element;

FIG. 3 is a schematic perspective view of an alternative embodiment of an adjustable element in accordance with the invention;

FIGS. 4A-4E are schematic side views of alternative embodiments of an adjustable element in accordance with the invention;

FIG. 5A is a schematic side view of the article of footwear of FIG. 1 showing select internal components;

FIG. 5B is an enlarged schematic view of a portion of the article of footwear of FIG. 5A;

FIG. 6 is a schematic top view of a portion of the sole of FIG. 2A with a portion of the sole removed to illustrate the layout of select internal components of the intelligent system;

FIG. 7 is an exploded schematic perspective view of a sole of the article of footwear of FIG. 1 in accordance with another embodiment of the invention;

FIGS. 8A-8G are schematic perspective views of various components that may be included in various embodiments of the sole of FIG. 7 in accordance with the invention;

FIG. 9 is a schematic bottom view of the midsole of FIGS. 7 and 8G in accordance with one embodiment of the invention;

FIG. 10 is a schematic bottom view of an optional torsional bar that may be used with the sole of FIG. 7 in accordance with one embodiment of the invention;

FIG. 11 is a schematic bottom view of the optional torsional bar of FIG. 10 disposed on the midsole of FIG. 9 in accordance with one embodiment of the invention;

FIG. 12 is a schematic bottom view of the midsole and the optional torsional bar of FIG. 11, further including additional heel foam elements in accordance with one embodiment of the invention;

FIG. 13 is a schematic bottom view of the midsole and the optional torsional bar of FIG. 11, further including additional components in accordance with one embodiment of the invention;

FIG. 14 is a schematic bottom view of the midsole of FIG. 13 further including the additional heel foam elements of FIG. 12 in accordance with one embodiment of the invention;

FIG. 15 is a schematic bottom view of the midsole of FIG. 14 further including a casing that covers the various components of the intelligent system in accordance with one embodiment of the invention;

FIG. 16 is a schematic lateral perspective view of a sole including a honeycombed shaped expansion element and a user interface in accordance with one embodiment of the invention;

FIG. 17 is a schematic lateral side view of the sole of FIG. 16;

FIG. 18 is an enlarged schematic lateral perspective view of the user interface of FIG. 16 in accordance with one embodiment of the invention;

FIG. 19 is an enlarged schematic lateral side view of the expansion element of FIG. 16 in accordance with one embodiment of the invention;

FIG. 20 is a schematic perspective view of the expansion element of FIG. 16 in accordance with one embodiment of the invention;

FIG. 21A is an exploded schematic perspective view of a motor and cushioning element for an article of footwear including an intelligent system, in accordance with one embodiment of the invention;

FIG. 21B is a schematic perspective view of the assembled motor and cushioning element of FIG. 21A;

FIG. 22 is an exploded schematic perspective view of a motor and gearbox, in accordance with one embodiment of the invention;

FIG. 23A is a schematic side view of a sole and user input for an article of footwear including an intelligent system, in accordance with one embodiment of the invention;

FIG. 23B is a schematic side view of the sole of FIG. 23A with an alternative user input;

FIG. 24 is an exploded schematic perspective view of an article of footwear including an intelligent system and further including a crash transition element, in accordance with one embodiment of the invention;

FIG. 25A is a schematic perspective view of a sole for an article of footwear including an intelligent system, in accordance with one embodiment of the invention;

FIG. 25B is an exploded schematic perspective view of the sole of FIG. 25A;

FIG. 26 is a block diagram of an intelligent system in accordance with the invention;

FIG. 27 is a flow chart depicting one mode of operation of the intelligent system of FIG. 1;

FIG. 28 is a flow chart depicting an alternative mode of operation of the intelligent system of FIG. 1;

FIG. 29 is a flow chart of a method for processing user inputs using the intelligent system of FIG. 1 in accordance with one embodiment of the invention;

FIG. 30 is a flow chart of a method for measuring a sensor signal using the intelligent system of FIG. 1 in accordance with one embodiment of the invention;

FIG. 31 is a flow chart of a method for determining whether a sole of an article of footwear has compressed using the intelligent system of FIG. 1 in accordance with one embodiment of the invention;

FIG. 32 is a flow chart of a method for monitoring the sensor signal to detect a compression in a sole of an article of footwear using the intelligent system of FIG. 1 in accordance with one embodiment of the invention;

FIG. 33 is a flow chart of a method for determining whether an adjustment of a sole of an article of footwear is required using the intelligent system of FIG. 1 in accordance with one embodiment of the invention;

FIG. 34 is a flow chart depicting an alternative mode of operation for an intelligent system in accordance with one embodiment of the invention;

FIG. 35 is a circuit diagram of one embodiment of the intelligent system of FIG. 1 for a left shoe;

FIG. 36 is a circuit diagram of one embodiment of the intelligent system of FIG. 1 for a right shoe;

FIG. 37 is a table that lists the states of the input/output at certain pins of the microcontroller of FIG. 35 that are required to turn on several combinations of the electro-luminescent elements of FIG. 35;

FIG. 38 is a table that lists the output that is required at certain pins of the microcontroller of FIG. 35 to drive the motor of the intelligent system;

FIG. 39A is a schematic side view of an article of footwear including an alternative embodiment of an intelligent system in accordance with the invention;

FIG. 39B is a schematic perspective view of a portion of the intelligent system of FIG. 39A;

FIG. 40A is a schematic side view of an article of footwear including yet another alternative embodiment of an intelligent system in accordance with the invention;

FIGS. 40B-40D are schematic side views of the intelligent system of FIG. 40A in various orientations;

FIG. 41A is a schematic side view of an article of footwear including yet another alternative embodiment of an intelligent system in accordance with the invention;

FIG. 41B is a schematic side view of the intelligent system of FIG. 41A throughout a range of adjustment;

FIG. 42 is a graph depicting a performance characteristic of a specific embodiment of an adjustable element;

FIG. 43 is a flow chart depicting one embodiment of a method of modifying a performance characteristic of an article of footwear during use;

FIGS. 44A and 44B are flow charts depicting additional embodiments of the method of FIG. 43; and

FIG. 45 is a flow chart depicting one embodiment of a method of providing comfort in an article of footwear.

DETAILED DESCRIPTION

Embodiments of the present invention are described below. It is, however, expressly noted that the present invention is not limited to these embodiments, but rather the intention is that modifications that are apparent to the person skilled in the art are also included. In particular, the present invention is not intended to be limited to any particular performance characteristic or sensor type or arrangement. Further, only a left or right shoe is depicted in any given figure; however, it is to be understood that the left and right shoes are typically mirror images of each other and the description applies to both left and right shoes. In certain activities that require different left and right shoe configurations or performance characteristics, the shoes need not be mirror images of each other.

FIG. 1 depicts an article of footwear 100 including an upper 102, a sole 104, and an intelligent system 106. The intelligent system 106 is laterally disposed in a rearfoot portion 108 of the article of footwear 100. The intelligent system 106 could be disposed anywhere along the length of the sole 104 and in essentially any orientation. In one embodiment, the intelligent system 106 is used to modify the compressibility of a heel area of the article of footwear 100. In another embodiment, the intelligent system 106 can be located in a forefoot portion 109 and can be moved into and out of alignment with a flex line or otherwise configured to vary a push-off characteristic of the footwear 100. In yet another embodiment, the footwear 100 could include multiple intelligent systems 106 disposed in multiple areas of the footwear 100. The intelligent system 106 is a self-adjusting system that modifies one or more performance characteristics of the article of footwear 100. The operation of the intelligent system 106 is described in detail hereinbelow.

FIG. 2A depicts an exploded view of a portion of the sole 104 of FIG. 1. The sole 104 includes a midsole 110, an outsole 112a, 112b, an optional lower support plate 114, an optional upper support plate 116, and the intelligent system 106. The upper and lower support plates may, among other purposes, be included to help constrain the intelligent system 106 in a particular orientation. The intelligent system 106 is disposed within a cavity 118 formed in the midsole 110. In one embodiment, the midsole 110 is a modified conventional midsole and has a thickness of about 10 mm to about 30 mm, preferably about 20 mm in the heel portion. The intelligent system 106 includes a control system 120 and an actuation system 130 in electrical communication therewith, both of which are described in greater detail hereinbelow. The actuation system 130 includes a driver 131 and an adjustable element 124. The control system 120 includes a sensor 122, for example a proximity sensor, a magnet 123, and electrical circuitry (see FIGS. 29-30). In the embodiment shown, the sensor 122 is disposed below the adjustable element 124 and the magnet 123 is vertically spaced from the sensor 122. In this particular embodiment, the magnet 123 is disposed above the adjustable element 124 and is a Neodymium Iron Bore type magnet. The actual position and spacing of the sensor 122 and magnet 123 will vary to suit a particular application, for example, measuring and modifying the compressibility of the sole. In this particular embodiment, the sensor 122 and magnet 123 are located in a spot that corresponds generally to where maximum compression occurs in the rearfoot portion 108 of the footwear 100. Typically, the spot is under the wearer's calcaneous. In such an embodiment, the sensor 122 and magnet 123 are generally centered between a lateral side and a medial side of the sole 104 and are between about 25 mm and about 45 mm forward of a posterior aspect of the wearer's foot.

FIG. 2B depicts a portion of the intelligent system 106, in particular the actuation system 130, in greater detail. The intelligent system 106 is preferably encased in a sealed, waterproof enclosure. The actuation system 130 generally includes a driver 131, which includes a motor 132 and a transmission element 134, and an adjustable element 124, which includes a limiter 128, an expansion element 126, and a stop 136. The embodiment of the particular driver 131 shown is a lead screw drive, made up of a bi-directional electric motor 132 and a threaded rod that forms the transmission element 134. In one embodiment, the motor 132 can be a radio-controlled servomotor of the type used in model airplanes. The threaded rod could be made of steel, stainless steel, or other suitable material.

The motor 132 is mechanically coupled to the transmission element 134 and drives the element 134 in either a clockwise or counter-clockwise direction as indicated by arrow 138. The transmission element 134 threadedly engages the limiter 128 and transversely positions the limiter 128 relative to the expansion element 126, as shown generally by arrow 140. Because the limiter 128 is threadedly engaged with the transmission element 134 and prevented from rotation relative to the motor 132 and the footwear 100, no power is required to maintain the limiter's position. There is sufficient friction in the actuation system 130 and a sufficiently fine thread on the transmission element 134 to prevent inadvertent rotation of the element 134 during a heel strike. In one example, the limiter 128 advances toward the expansion element 126 (forward) when the motor 132 drives the transmission element 134 in the clockwise direction and the limiter 128 moves away from the expansion element 126 (backward) when the motor 132 drives the transmission element 134 in the counter-clockwise direction. Alternatively, other types of drivers are possible. For example, the driver 131 could be essentially any type of rotary or linear actuator, a gear train, a linkage, or combinations thereof.

The expansion element 126 is generally cylindrical, with an elongated circular or elongated generally elliptically-shaped cross-section, or it includes a series of arched walls with different centers, but identical radii, or any combination thereof. The arcuate ends of the expansion elements are not necessarily semi-circular in shape. The radius of the arcuate ends will vary to suit a particular application and can be varied to control the amount of longitudinal expansion of the expansion element 126 when under compressive loading vertically. In general, the larger the radius of the arcuate end, the greater longitudinal expansion is possible under vertical compression loading. The expansion element 126 has a solid outer wall 142 and a optional compressible core 144 of foam or other resilient material. The size, shape, and materials used in the expansion element 126 will be selected to suit a particular application. In the embodiment shown, the transmission element 134 extends through the expansion element 126 and connects to a stop 136. The stop 136 prevents movement of the expansion element 126 in a direction away from the limiter 128. Alternatively, the stop 136 could be a rear wall of the cavity 118.

The general operation of the adjustable element 124 is described with respect to an application where the intelligent system 106 is used to modify cushioning in the article of footwear 100 in response to a measured parameter, for example compression of the midsole 110. The expansion element 126 is allowed to compress when acted on by a vertical force, depicted generally by arrows 146. The expansion element 126 expands in the horizontal direction (arrow 148) when compressed. The limiter 128 is used to control this movement. As the horizontal movement is limited, the vertical movement is limited as well. The expansion element 126 has a bi-modal compression response, which is discussed in greater detail below with respect to FIG. 42.

The intelligent system 106 can control the amount of compression a user creates in the article of footwear 100. As an example, when a user wearing the article of footwear 100 engages a ground surface during a stride, the vertical force 146 is applied to the expansion element 126 via the sole 104. The force 146 causes the expansion element 126 to expand during ground contact until it contacts the limiter 128, thereby controlling the compression of the sole 104.

During compression, the sensing portion of the control system 120 measures field strength of the magnet 123. In the embodiment shown, the sensor 122 is disposed proximate the bottom of the midsole 110 and the magnet 123 is disposed proximate the top of the midsole 110. The magnetic field strength detected by the sensor 122 changes as the magnet 123 moves closer to the sensor 122, as the midsole 110 is compressed. The system can be calibrated, such that this magnetic field strength can be converted to a distance. It is the change in distance that indicates how much the midsole 110 has been compressed. The control system 120 outputs a signal to the actuation system 130 based on the change in distance or compression measurement.

The actuation system 130 then modifies the hardness or compressibility of the midsole 110 based on the signal received from the control system 120. The actuation system 130 utilizes the transmission element 134 as the main moving component. The operation of the intelligent system 106 is described in greater detail below, with respect to the algorithms depicted in FIGS. 22-28.

FIG. 3 depicts a portion of an alternative embodiment of an intelligent system 306 in accordance with the invention, in particular the actuation system 330. The actuation system 330 includes a driver 331 and an adjustable element 324. The adjustable element 324 includes an expansion element 326 and limiter 328 similar to that described with respect to FIG. 2B. The driver 331 includes a motor 332 and a transmission element 334, in this embodiment a hollow lead screw 325 through which a cable 327 passes. The cable 327 runs through the expansion element 326 and has a stop 336 crimped to one end. The limiter 328 is a generally cylindrically-shaped element that is slidably disposed about the cable 327 and acts as a bearing surface between the screw 325 and the expansion element 326, in particular a bearing arm 339 coupled to the expansion element 326. A similar bearing arm is disposed proximate the stop 336, to distribute loads along the depth of the expansion element 326. In one embodiment, the motor 332 is a 8-10 mm pager motor with a 50:1 gear reduction. The cable 327, screw 325, limiter 328, and bearing arm 339 may be made of a polymer, steel, stainless steel, or other suitable material. In one embodiment, the cable 327 is made from stainless steel coated with a friction-reducing material, such as that sold by DuPont under the trademark Teflon®.

In operation, the cable 327 is fixedly attached to the driver 331 and has a fixed length. The cable 327 runs through the screw 325, which determines the amount of longitudinal travel of the expansion element 326 that is possible. For example, as a vertical force is applied to the expansion element 326, the element 326 expands longitudinally along the cable 327 until it hits the limiter 328, which is disposed between the expansion element 326 and the end of the screw 325. The motor 332 rotates the screw 325 to vary the length of the cable 327 that the limiter 328 can slide along before contacting the screw 325 and expansion element 326. The screw 325 moves a predetermined distance either towards or away from the element 326 in response to the signal from the control system. In one embodiment, the screw 325 may travel between about 0 mm to about 20 mm, preferably about 0 mm to about 10 mm.

In an alternative embodiment, the adjustable element 324 includes two motors 332 and cables 327 oriented substantially parallel to one another. Two cables 327 aid in holding the expansion element 326 square relative to a longitudinal axis 360 of the adjustable element 324 depicted in FIG. 3. In addition, other types of expansion element/limiter arrangements are possible. For example, a circumferential or belly band type limiter may be used instead of a diametral or longitudinal type limiter. In operation, the driver 331 varies the circumference of the belly band to vary the range of expansion of the element 326, the larger the circumference, the larger the range of expansion. Other possible arrangements include shape memory alloys and magnetorheological fluid.

FIGS. 4A-4E depict alternative adjustable elements, with each shown in an unloaded state. In particular, FIGS. 4A-4D depict certain different possible shapes for the expansion element. In FIG. 4A, the expansion element 426 includes two cylinders 428 having generally elliptically-shaped cross-sections and formed as a single element. Alternatively, the cylinder cross-sectional shape could be any combination of linear and arcuate shapes, for example, hexagonal or semi-circular. The cylinders 428 include a wall 432 and a pair of cores 434 that may be hollow or filled with a foam or other material. FIG. 4B depicts an expansion element 446 having two separate cylinders 448 having generally circular cross-sections and coupled together. The cylinders 448 each have a wall 452 and a core 454. FIG. 4C depicts an expansion element 466 including two cylinders 448 as previously described. In FIG. 4C, the expansion element 466 includes a foam block 468 surrounding the cylinders 448. The foam block 468 may replace the core or be additional to the core. FIG. 4D depicts yet another embodiment of an expansion element 486. The expansion element 486 includes a cylinder 488 having an elongate sector cross-sectional shape. The cylinder includes a wall 492 and a core 494. The cylinder 488 includes a first arcuate end 496 and a second arcuate end 498. The first arcuate end 496 has a substantially larger radius than the second arcuate end 498, thereby resulting in greater horizontal displacement at the first arcuate end when under load. Additionally, the wall thickness of any cylinder can be varied and/or the cylinder could be tapered along its length. In embodiments of the expansion element 126 that use a foam core, it is undesirable to bond the foam core to the walls of the expansion element 126. Bonding the foam to the walls may inhibit horizontal expansion.

FIG. 4E depicts an alternative type of adjustable element 410. The adjustable element 410 includes a relatively flexible structural cylinder 412 and piston 414 arrangement. The internal volume 416 of the cylinder 412 varies as the piston 414 moves into and out of the cylinder 412, shown generally by arrow 418. The piston 414 is moved linearly by the driver 131 in response to the signal from the control system 120. By varying the volume 416, the compressibility of the cylinder 412 is varied. For example, when the piston 414 is moved into the cylinder 412, the volume is reduced and the pressure within the cylinder is increased; the greater the pressure, the harder the cylinder. While this system may appear similar to that of an inflatable bladder, there are differences. For example, in this system, the amount of fluid, e.g., air, stays constant, while the volume 416 is adjusted. Further, bladders primarily react based on the pressure within the bladder, whereas the element 410 depicted in FIG. 4E uses the structure of the cylinder in combination with the internal pressure. The two are fundamentally different in operation. For example, the inflatable bladder, like a balloon, merely holds the air in and provides no structural support, while the cylinder, like a tire, uses the air to hold up the structure (e.g. the tire sidewalls). In addition, the piston 414 and driver 131 arrangement allows for fine adjustment of the pressure and compressibility of the adjustable element 410.

FIG. 5A depicts a side view of the article of footwear 100 of FIG. 1. The intelligent system 106 is disposed generally in the rearfoot portion 108 of the article of footwear 100. As shown in FIG. 5A, the intelligent system 106 includes the adjustable element 124 with the limiter 128 and the driver 131. Also shown is a user-input module 500 (FIG. SB) including user-input buttons 502, 504 and an indicator 506. The user can set the compression range or other performance characteristic target value of the article of footwear 100, by pushing input button 502 to increase the target value or pushing input button 504 to decrease the target value or range. In an alternative embodiment, the user-input module 500 can be remotely located from the shoe. For example, a wristwatch, personal digital assistant (PDA), or other external processor could be used alone or in combination with the user-input module 500 disposed on the article of footwear, to allow the user to customize characteristics of the intelligent system 106. For example, the user may press buttons on the wristwatch to adjust different characteristics of the system 106. In addition, the system 106 may include an on and off switch.

The user-input module 506 is shown in greater detail in FIG. 5B. The indicator(s) 506 may be one or more electro-luminescent elements, for example. In the embodiment shown, the indicator 506 is a series of electro-luminescent elements printed on a flex-circuit that glow to indicate the range of compression selected; however, the indicators could also indicate the level of hardness of the midsole or some other information related to a performance characteristic of the footwear 100. Alternatively or additionally, the indicator may be audible.

FIG. 6 depicts a top view of one possible arrangement of select components of the intelligent system of FIG. 1. The adjustable element 124 is disposed in the rearfoot portion 108 of the midsole 110 with the expansion element 126 laterally disposed within the cavity 118. The driver 131 is disposed adjacent to the expansion element 126. Adjacent to the driver 131 is the control system 120. The control system 120 includes a control board 152 that holds a micro-controller for controlling the driver 131 and for processing the algorithm. Further, the system 106 includes a power source 150, for example a 3.0V ½ AA battery. The power source 150 supplies power to the driver 131 and the control system 120 via wires 162 or other electrical connection, such as a flexcircuit.

The system 106 further includes the magnet 123 and the aligned sensor 122 (not shown), which is located under the expansion element 126 and is electrically coupled to the control system 120. The magnet 123 is located above the expansion element 126, but below an insole and/or sock liner. Further, the entire intelligent system 106 can be built into a plastic casing to make the system 106 waterproof. In addition, the system 106 can be built as a single module to facilitate fabrication of the sole 104 and may be pre-assembled to the lower support plate 114 (not shown in FIG. 6). In one embodiment, the system 106 is removable, thereby making the system 106 replaceable. For example, the outsole 112a, 112b may be configured (e.g., hinged) to allow the system to be removed from the cavity 118 of the midsole 110.

The system 106 may also include an interface port 160 that can be used to download data from the intelligent system 106, for example to a PDA or other external processor. The port 106 can be used to monitor shoe performance. In an alternative embodiment, the data can be transmitted (e.g., via radio waves) to a device with a display panel located with the user. For example, the data can be transmitted to a wristwatch or other device being worn the user. In response to the data, the user may adjust certain characteristics of the shoe by pressing buttons on the wristwatch, as described above. These adjustments are transmitted back to the system 106 where the adjustments are implemented.

FIG. 7 depicts an exploded perspective view of a sole 204 of the article of footwear 100 of FIG. 1 in accordance with another embodiment of the invention. The sole 204 includes a midsole 210, an outsole 212, an optional lower support plate 214, and an optional upper support plate 216. A rearfoot portion 208 of the sole 204 may be made from, for example, a foam, such as a polyurethane (PU) or ethylene vinyl acetate (EVA) foam, and may be adapted to receive an expansion element 226. In one embodiment, the expansion element 226 is, as shown, shaped like a honeycomb; however, the element 226 may also be generally cylindrical, with an elongated circular or elongated generally elliptically-shaped cross-section, or include a series of arched walls with different centers, but identical radii, or any combination thereof. A motor 232 is also positioned within the sole 204 and may be used to adjust the expansion element 226. A user interface 254, including user input buttons 256, may also be provided for receiving user inputs related to the adjustment of the sole 204.

FIGS. 8A-8G depict perspective views of various components that may be included in various embodiments of the sole 204. The components include the motor 232 (FIG. 8A), the expansion element 226 (FIG. 8B), the optional lower support plate 214 (FIG. 8C), the user interface 254 and the user input buttons 256 (FIG. 8D), the rearfoot portion 208 that may be made from, for example, the PU or EVA foam (FIG. 8E), the optional upper support plate 216 (FIG. 8F), and the midsole 210 (FIG. 8G).

FIG. 9 depicts a bottom view of the midsole 210 of FIGS. 7 and 8G. The midsole 210 includes an opening 257 for accessing the power source 150 (see FIG. 6) and related equipment used in the intelligent system 106. The position of the opening 257 in the midsole 210 can vary depending on the location of the power source 150 and related equipment in the sole 204.

FIG. 10 depicts a bottom view of an optional torsional bar 258 that may be used with the sole 204 of FIG. 7 in accordance with one embodiment of the invention. The torsional bar 258 may include openings 264a, 264b at the heel and at the shank. The openings 264 may provide clearance for, or access to, the various components of the intelligent system 106.

FIG. 11 depicts a bottom view of the optional torsional bar 258 of FIG. 10 disposed on the midsole 210 illustrated in FIG. 9 in accordance with one embodiment of the invention. The opening 264b on the torsional bar 258 aligns with the opening 257 in the midsole 210 to enable a user to access the power source 150 and related equipment in the sole 204.

FIG. 12 depicts a bottom view of the midsole 210 and the optional torsional bar 258 of FIG. 11, further including additional heel foam elements 266a, 266b, 266c in accordance with one embodiment of the invention. The illustrated embodiment includes three heel foam elements: (1) a rear foam element 266a extending from a medial to a lateral side of the midsole 210; (2) a medial front foam 266b element; and (3) a lateral front foam element 266c. The hardness of the foam elements 266 may vary to suit a particular application. For example, the lateral front foam element 266c may be harder than the rear foam element 266a. The material properties may vary between and within the different foam elements 266 to perform different functions, for example, to guide the foot into a neutral position between pronation and supination during a step cycle. The use of foam elements for cushioning and guidance is described in greater detail in U.S. Pat. No. 6,722,058 and U.S. patent application Ser. No. 10/619,652, the disclosures of which are hereby incorporated by reference herein in their entireties. Details of additional structural elements that can be used in an article of footwear with an intelligent system are described in greater detail in U.S. patent application Ser. No. 11/346,998, the disclosure of which is hereby incorporated by reference herein in its entirety.

FIG. 13 depicts a bottom view of the midsole 210 and the optional torsional bar 258 of FIG. 11, further including the motor 232 and the power source 150 disposed in the openings 257, 264b that extend through the midsole 210 and optional torsional bar 258, the user interface 254, and the expansion element 226 in accordance with one embodiment of the invention. Alternatively or additionally, the expansion element 226 could be located in the forefoot area of the sole 204, or at substantially any position along the sole 204. In addition, the orientation of the expansion element 226 in the sole 204 can be varied to suit a particular application. For example, in one embodiment, the intelligent system could be located on only the medial or lateral side to provide a controlled dual density sole, one part of which would be automatically adjustable.

FIG. 14 depicts a bottom view of the midsole 210 of FIG. 13 further including the additional heel foam elements 266a, 266b, 266c of FIG. 12 in accordance with one embodiment of the invention. In the illustrated embodiment, the expansion element 226 is shown embedded between the three foam elements 266a, 266b, 266c.

FIG. 15 depicts a bottom view of the midsole 210 of FIG. 14 further including a casing 270 that covers the power source 150 and other electronic components in accordance with one embodiment of the invention. The casing 270 can optionally be removed to enable a user to access the power source 150 and other electronic equipment.

FIG. 16 is a lateral perspective view of the sole 204 including the honeycombed shaped expansion element 226 and the user interface 254 that may be used to alter the settings of the intelligent system 106 in accordance with one embodiment of the invention. In various embodiments, the sole 204 can include multiple expansion elements 226. A cable element (not shown) may extend between the medial front foam element 266b and the lateral front foam element 266c, and also between the rear foam elements 266a. The expansion elements 226 can be coupled together by the cable passing therethrough. The user interface 254 includes buttons 256 to increase (+) and/or decrease (−) the performance characteristic(s) of the intelligent system 106 and electro-luminescent elements 268 to indicate the system setting.

FIG. 17 is a lateral side view of the sole 204 of FIG. 16, where the expansion element 226 is more fully illustrated. The expansion element 226 is, as shown, shaped like a honeycomb; however, the element 226 may also be generally cylindrical, with an elongated circular or elongated generally elliptically-shaped cross-section, or include a series of arched walls with different centers, but identical radii, or any combination thereof.

FIG. 18 is an enlarged lateral view of the user interface 254 of FIG. 16 illustrating the buttons 256 that are used to increase (+) and/or decrease (−) the performance characteristic(s) provided by the intelligent system 106 and the electro-luminescent elements 268 that indicate the system setting in accordance with one embodiment of the invention.

FIG. 19 is an enlarged lateral side view of the expansion element 226 of FIG. 16 illustrating its honeycomb shape in accordance with one embodiment of the invention. In addition, a cable 327 is shown running through the middle of the expansion element 226.

FIG. 20 depicts a perspective view of the expansion element 226 of FIG. 16 in accordance with one embodiment of the invention. The expansion element 226 has four generally vertical side walls 272 (two on each side), whereby a generally horizontal bar 274 connects the adjacent side walls 272 on each side to each other, thereby forming the generally honeycomb-like structure. The horizontal bar 274 is generally centrally disposed between the side walls 272. The horizontal bars 274 provide stability against shear forces in a longitudinal direction and in some instances may be under tension. In one embodiment, the side walls 272 have a generally arcuate shape; however, the side walls 272 and the horizontal bar 274 can be linear, arcuate, or combinations thereof. The expansion element 226 may also include a top bar 276 and a bottom bar 278.

FIG. 21A depicts one example of a motor and cushioning element assembly for an article of footwear including an intelligent system. The arrangement 3000 includes a cushioning element 3010 that is connected by a cable assembly 3020 to a gear arrangement 3030 and a motor 3040. The motor 3040 and gear arrangement 3030 are housed in a gearbox 3050, which is in turn housed within a main housing 3060. The main housing 3060 can hold a battery 3070 in place by, for example, a clip 3080. An O-ring 3090 and battery lid 3100 can then be mounted on the housing 3060 and can provide a waterproof seal over the battery 3070, thus protecting the motor 3040, gearbox 3050, and associated electronics from any damaging moisture or other contaminants, such as, but not limited to, water, mud, dust, and perspiration.

The motor 3040, gearbox 3050, and associated electronics can be further protected from the elements by a gasket 3110 and an end cover 3120. An O-ring 3170 can be placed on a ferrule 3160, covering the cable assembly 3020, to provide a waterproof seal to stop contaminants from entering the gearbox 3050 around the cable assembly 3020. The cable assembly 3020 can then be inserted through the cushioning element 3010 and held in place by crossbars 3130 and 3140. Upon assembling the arrangement 3000, the cushioning element 3010 can be adjusted through signals from a control system connected to the motor 3040 by electrical circuitry 3180. A magnet 3150 can be used, in an example embodiment, to provide a means of obtaining a signal relating to the compression of the cushioning element 3010, as described previously.

Providing O-rings, a gasket, and, end covers for the gearbox 3050, cable assembly 3020, and battery compartment allows the motor and gear assembly to be maintained waterproof. This can be advantageous in protecting the gearbox arrangement from the elements, including water, mud, dust, sand, or other contaminants that an athletic shoe may be exposed to. The waterproof arrangement can also protect the gearbox from moisture generated through perspiration by the shoe's wearer. This protection will result in an extension of the working life of the assembly and a possible increase in the efficiency of the assembly.

The assembled motor and cushioning element arrangement 3000 can be seen in FIG. 21B. As can be seen, the cable assembly 3020 connects the cushioning element 3010 to the gearbox 3050 housed in the main housing 3060. The gasket 3110 and end covering 3120 provide protection for the gearbox 3050 and the motor 3040. The electrical circuitry 3180 connects to the battery 3070, the motor 3040, and associated electronics within the main housing 3060, and to a sensor embedded within the cushioning element 3010.

An exploded view of the gearbox 3050, motor 3040, and gear arrangement 3030 can be seen in FIG. 22. Also shown are the main axle 3020, and a secondary axle 3200 for elements of the gear arrangement 3030. A sensing means 3190 can be placed on the motor assembly to provide a means of accurately determining the rotation of the shaft 3210 of the motor 3040, or the rotation of a gear or other rotating component. In one embodiment, the sensing means 3190 can be a magnetic sensor or a magnet attached to a separate sensor located on the electrical circuitry 3180, with the location of the sensing means 3190 corresponding to the location of a magnet positioned on the shaft 3210. This arrangement allows the sensing means 3190 to accurately determine the number of revolutions and/or angular position of the shaft 3210, with the sensing means 3190 recognizing a full rotation of the shaft 3210 every time the magnet placed upon the shaft 3210 passes next to the sensing means 3190. The sensing means 3190 can also be used to determine the rotation of a gear, or other rotating component. In alternative embodiments, different means of determining the rotation of the shaft 3210 can be used, such as, but not limited to, employing a mechanical, electrical, or optical sensor to measure a full or partial rotation of the shaft 3210.

One embodiment of a sole and user input for an article of footwear including an intelligent system is shown in FIG. 23A. In this embodiment, a user input housing 3320 is mounted to a sole unit 3310. The user input housing 3320 provides a means for a wearer to adjust the settings for the cushioning element embedded within the sole 3310. In one embodiment, the user input can include two buttons embedded within the user input housing 3320. These buttons can allow the wearer to input a positive input 3340 and/or a negative input 3330 into the controller of the cushioning element. For example, a positive input 3340 may be used to increase the user preferred stiffness of a cushioning element, while a negative input 330 may be used to decrease the user preferred stiffness of the cushioning element. In one alternative embodiment, the positive input 3340 and negative input 3330 can be used to increase or decrease a threshold compression that determines when the motor and controller automatically adjust the resistance of the cushioning element. In further embodiments, pushing one or more of these buttons may be used to turn the motor and controller on and/or off, set the controller to run a different control algorithm, or adjust another element of the controller and/or motor function.

In a further alternative embodiment, the positive input 3340 and negative input 3330 can be replaced by a single capacitive user interface running between a positive end and negative end of the user input housing 3320. This interface may be, for example, resistance based or capacitance based. In this embodiment, adjustment of the cushioning, or any other user defined input described above, can be enabled by sliding a digit along the user input in either a positive or negative direction, in a manner similar to that used to control touch sensitive computer mousepads or by simply touching the user interface in a certain location such as on the “+” or “−”. Further alternative user inputs may include a dial, slider, or other appropriate input mechanism.

FIG. 23B shows an alternative sole and user input for an article of footwear including an intelligent system. In this embodiment, an alternative user input housing 3350 is attached to the sole 3310. In this embodiment, the user input includes a substantially circular or oval capacitive user interface that provides a signal to the control system through movement of a user's digit over the surface of the interface. Here, a positive adjustment of the stiffness can be provided by a clockwise rotation 3370 of the digit over the surface of the interface, while a negative adjustment of the stiffness can be provided by a counter-clockwise rotation 3380 of a user's digit over the interface surface. As described above, the interface can be set to adjust a variety of parameters of the control system and motor, depending upon the requirements of the user or the particular shoe.

Multiple input mechanisms are also contemplated. For example, the circular or oval capacitive user interface can be combined with a further, separate input 3380 to provide the user with greater control of the system and motor. The input 3380 can include any of the user interface mechanisms described above.

An exploded view of an article of footwear 3400 including an intelligent system can be seen in FIG. 24. This embodiment includes a top plate 3450 that is attached to the upper 3460 of the article of footwear 3400 and houses a motor 3470 and other elements of the intelligent system. A number of elliptical structures 3480 are over molded onto the top plate 3450 to provide cushioning to the forefoot area of the sole of the article of footwear 3400. A bottom plate 3490 can then be molded, or otherwise fitted, to the elliptical structures 3480 and/or other sole elements to complete the sole of the article of footwear 3340.

This example embodiment also includes a crash transition element 3430 that is surrounded by two independently tuned guidance structures 3440. The crash transition element 3430 and guidance structures 3440 are located in the heel region of the article of footwear. In one embodiment, the crash transition element 3430 is a structural cushioning element, the compressibility of which can be adjusted by the intelligent system 106. Alternatively, the crash transition element 3430 can be a structural element that can be adjusted to affect other performance characteristics of the shoe. Further, the crash transition element 3430 can be configured to respond rapidly to a signal from the intelligent system 106.

This embodiment includes a further alternative user input interface 3410, including two buttons providing a positive and negative user input. The user input interface 3410 can also include a series of LEDs 3420, what can provide the user with a visual indication of the setting of the cushioning control system. This user input interface can be replaced, in alternative embodiments, by any of the user inputs described previously.

FIG. 25A shows a partially exploded schematic perspective view of the sole of an article of footwear including an intelligent system, for use with a basketball shoe. In this embodiment, the sole 3500 includes a battery 3510, a motor and gear assembly 3520, and a cushioning element 3530, all embedded within a molded sole 3540. In this configuration, the battery 3510 is placed in front of the motor and gear assembly 3520, rather than on top of the motor assembly. This placement of the battery 3510 can decrease the overall height of the system, allowing the control system to be embedded in thinner soles. This can be advantageous in shoes such as those required for basketball, indoor soccer, squash, or other aerobic activities, where it is preferable to have a thinner sole in order to place the wearer's foot closer to the ground to facilitate turning, jumping, landing, cutting, starting and stopping rapidly, and other movements with such activities.

In this configuration, the battery 3510 is placed in front of the motor and gear assembly 3520 in the midsole region of the molded sole 3540. It may be advantageous to place the battery in this region as in many activities it is subject to lower compressive loads than the heel and forefoot regions of the sole. The battery compartment can be accessed through the upper side of the molded sole 3540 in order to insert and replace a battery 3510 when required. In alternative embodiments, the battery compartment can be accessed through the bottom or a side of the molded sole 3540.

In alternative embodiments of the invention, the battery 3510 can be placed at a number of different locations within the sole or upper of an article of footwear including an intelligent system, depending upon the specific shoe design and user requirements. For example, compartments for the battery, or batteries, can be placed at locations including, but not limited to, the forefoot or heel portions of the sole, on the side of the sole, on the rear of the shoe at the heel, or at a location on the upper of the shoe.

FIG. 25B is an exploded view of the sole of FIG. 25A. The sole 3500 includes an outsole 3550, a support element 3560, a lower support plate 3570, a rearfoot portion 3580, an upper support plate 3590, and a midsole 3600. An adjustable expansion element 3610, a motor 3620, and a power source 3630 are embedded within the sole 3500 between the lower support plate 3570 and the midsole 3600. The power source 3630 can be a battery, or any other appropriate means for providing power to the motor 3620. A user interface 3640 can be attached to a side of the assembled sole 3500 to provide a user with means of adjusting the functions of the expansion element 3610 and motor 3620 assembly. A sensor 3650 and sensor cover 3660 can be located below the expansion element 3610.

Upon construction, the motor 3620 and the power source 3630 are inserted into a cavity 3670 in the midsole 3600. In certain embodiments, access to the power source 3630 can be gained through an opening in the upper surface of the midsole 3600, while in other embodiments the power source 3630 can be accessed through on opening on the bottom or side of the sole 3500. In further embodiments, one or more elements of the sole 3500, such as the support element 3560, the lower support plate 3570, or the upper support plate 3590, may not be required, depending upon the specific style of shoe being constructed.

A block diagram of one embodiment of an intelligent system 706 is shown in FIG. 26. The intelligent system 706 includes a power source 750 electrically coupled to a control system 720 and an actuation system 730. The control system 720 includes a controller 752, for example one or more micro-processors, and a sensor 722. The sensor may be a proximity-type sensor and magnet arrangement. In one embodiment, the controller 152 is a microcontroller such as the PICMicro® microcontroller manufactured by Microchip Technology Incorporated of Chandler, Ariz. In another embodiment, the controller 752 is a microcontroller manufactured by Cypress Semiconductor Corporation. The actuation system 730 includes a driver 731, including a motor 732 and a transmission element 734, and an adjustable element 724. The driver 731 and control system 720 are in electrical communication. The adjustable element 724 is coupled to the driver 731.

Optionally, the actuation system 730 could include a feedback system 754 coupled to or as part of the control system 720. The feedback system 754 may indicate the position of the adjustable element 724. For example, the feedback system 754 can count the number of turns of the motor 732 or the position of the limiter 728 (not shown). The feedback system 754 could be, for example, a linear potentiometer, an inductor, a linear transducer, or an infrared diode pair.

FIG. 27 depicts one possible algorithm for use with the intelligent system 106. The intelligent system 106 measures a performance characteristic of a shoe during a walk/run cycle. Before the system 106 begins to operate, the system 106 may run a calibration procedure after first being energized or after first contacting the ground surface. For example, the system 106 may actuate the adjustable element 124 to determine the position of the limiter 128 and/or to verify the range of the limiter 128, i.e., fully open or fully closed. During operation, the system 106 measures a performance characteristic of the shoe (step 802). In one embodiment, the measurement rate is about 300 Hz to about 60 KHz. The control system 120 determines if the performance characteristic has been measured at least three times (step 804) or some other predetermined number. If not, the system 106 repeats step 802 by taking additional measurements of the performance characteristic until step 804 is satisfied. After three measurements have been taken, the system 106 averages the last three performance characteristic measurements (step 806). The system 106 then compares the average performance characteristic measurement to a threshold value (step 808). At step 810, the system 106 determines if the average performance characteristic measurement is substantially equal to the threshold value. If the average performance characteristic measurement is substantially equal to the threshold value, the system 106 returns to step 802 to take another performance characteristic measurement. If the average performance characteristic measurement is not substantially equal to the threshold value, the system 106 sends a corrective driver signal to the adjustable element 124 to modify the performance characteristic of the shoe. The intelligent system 106 then repeats the entire operation until the threshold value is reached and for as long as the wearer continues to use the shoes. In one embodiment, the system 106 only makes incremental changes to the performance characteristic so that the wearer does not sense the gradual adjustment of the shoe and does not have to adapt to the changing performance characteristic. In other words, the system 106 adapts the shoe to the wearer, and does not require the wearer to adapt to the shoe.

Generally, in a particular application, the system 106 utilizes an optimal midsole compression threshold (target zone) that has been defined through testing for a preferred cushioning level. The system 106 measures the compression of the midsole 110 on every step, averaging the most recent three steps. If the average is larger than the threshold then the midsole 110 has over-compressed. In this situation, the system 106 signals the driver 131 to adjust the adjustable element 124 in a hardness direction. If the average is smaller than the threshold, then the midsole 110 has under-compressed. In this situation, the system 106 signals the driver 131 to adjust the adjustable element in a softness direction. This process continues until the measurements are within the target threshold of the system. This target threshold can be modified by the user to be harder or softer. This change in threshold is an offset from the preset settings. All of the above algorithm is computed by the control system 120.

In this particular application, the overall height of the midsole 110 and adjustable element 124 is about 20 mm. During testing, it has been determined that an optimal range of compression of the midsole 110 is about 9 mm to about 12 mm, regardless of the hardness of the midsole 110. In one embodiment, the limiter 128 has an adjustment range that corresponds to about 10 mm of vertical compression. The limiter 128, in one embodiment, has a resolution of less than or equal to about 0.5 mm. In an embodiment of the system 106 with user inputs, the wearer may vary the compression range to be, for example, about 8 mm to about 11 mm or about 10 mm to about 13 mm. Naturally, ranges of greater than 3 mm and lower or higher range limits are contemplated and within the scope of the invention.

During running, the wearer's foot goes through a stride cycle that includes a flight phase (foot in the air) and a stance phase (foot in contact with the ground). In a typical stride cycle, the flight phase accounts for about ⅔ of the stride cycle. During the stance phase, the wearer's body is normally adapting to the ground contact. In a particular embodiment of the invention, all measurements are taken during the stance phase and all adjustments are made during the flight phase. Adjustments are made during the flight phase, because the shoe and, therefore, the adjustable element are in an unloaded state, thereby requiring significantly less power to adjust than when in a loaded state. In most embodiments, the shoe is configured such that the motor does not move the adjustable element; therefore lower motor loads are required to set the range of the adjustable element. In the embodiments depicted in FIGS. 39, 40, and 41, however, the adjustable element does move, as described in greater detail hereinbelow.

During operation, the system 106 senses that the shoe has made contact with the ground. As the shoe engages the ground, the sole 104 compresses and the sensor 122 senses a change in the magnetic field of the magnet 123. The system 106 determines that the shoe is in contact with the ground when the system 106 senses a change in the magnetic field equal to about 2 mm in compression. It is also at this time that the system 106 turns off the power to the actuation system 130 to conserve power. During the stance phase, the system 106 senses a maximum change in the magnetic field and converts that measurement into a maximum amount of compression. In alternative embodiments, the system 106 may also measure the length of the stance phase to determine other performance characteristics of the shoe, for example velocity, acceleration, and jerk.

If the maximum amount of compression is greater than 12 mm, then the sole 104 has over-compressed, and if the maximum amount of compression is less than 9 mm, then the sole 104 has under-compressed. For example, if the maximum compression is 16 mm, then the sole 104 has over-compressed and the control system 120 sends a signal to the actuation system 130 to make the adjustable element 124 firmer. The actuation system 130 operates when the shoe is in the flight phase, i.e., less than 2 mm of compression. Once the system 106 senses that the compression is within the threshold range, the system 106 continues to monitor the performance characteristic of the shoe, but does not further operate the actuation system 130 and the adjustable element 124. In this way, power is conserved.

In alternative embodiments, the intelligent system 106 can use additional performance characteristics alone or in combination with the optimal midsole compression characteristic described above. For example, the system 106 can measure, in addition to compression, time to peak compression, time to recovery, and the time of the flight phase. These variables can be used to determine an optimum setting for the user, while accounting for external elements such as ground hardness, incline, and speed. Time to peak compression is described as the amount of time that it takes from heel strike to the maximum compression of the sole while accounting for surface changes. It may be advantageous to use the area under a time versus compression curve to determine the optimum compression setting. This is in effect a measure of the energy absorbed by the shoe. In addition, the time of the flight phase (described above) can contribute to the determination of the optimum setting. The stride frequency of the user can be calculated from this variable. In turn, stride frequency can be used to determine changes in speed and to differentiate between uphill and downhill motion.

FIG. 28 depicts another possible algorithm that may be performed by the intelligent system 106. In particular, FIG. 28 illustrates one embodiment of a method 2300 for modifying a performance characteristic of the article of footwear 100 during use. At step 2500 of the method 2300, the intelligent system 106 measures a sensor signal from the sensor 122. The intelligent system 106 then determines, at step 2600, whether the sole 104 has compressed. Alternatively or additionally, the system 106 can determine if the user has engaged in any of various activities, for example running, cutting, jumping, or landing, to which the system 106 can adjust a performance characteristic in response thereto. Upon determining that the sole 104 has compressed, the intelligent system 106 performs initial calculations, at step 2700, to determine whether an adjustment of the sole 104 is required. At step 2800, the intelligent system 106 performs additional calculations to determine further or alternatively whether an adjustment of the sole 104 is required. If an adjustment of the sole 104 is required, the intelligent system 106 also adjusts the sole 104 at step 2800. FIGS. 25, 26, 27, and 28, which follow, describe methods for implementing the steps 2500, 2600, 2700, and 2800, respectively, of the method 2300.

The method 2300 begins by providing power to the intelligent system 106. For example, a battery may act as the power source 150 and may be installed in the intelligent system 106 at step 2304. Once the battery is installed in the intelligent system 106, the intelligent system 106 may run an “ON” sequence at step 2308. For example, the intelligent system 106 may light the electro-luminescent elements of the indicator 506 in a manner that signals to a user of the article of footwear 100 that the intelligent system 106 is active. Where the battery is already installed in the intelligent system 106, but a user of the article of footwear 100 has previously turned the intelligent system 106 off (as described below), the user may turn the intelligent system 106 on and activate the “ON” sequence by pressing, for example, one or more of the user-input buttons 502, 504 at step 2312.

Once the intelligent system 106 is on, the intelligent system 106 may check for user input at step 2316. In the embodiments depicted in FIGS. 28-33, the user indicates a desire to increase hardness of the sole 104 by pressing the “+” button 502, and a desire to decrease the hardness of the sole 104 (i.e., increase the softness of the sole 104) by pressing the “−” button 504. If user input is received from a user of the article of footwear 100, as determined at step 2320, the intelligent system 106 processes the user input at step 2400. FIG. 29, which follows, describes a method implementing the step 2400 of the method 2300. If user input is not received, the intelligent system 106 measures the sensor signal from the sensor 122 at step 2500.

Optionally, the method 2300 may include a self diagnostic and user analysis/interaction step 2324. More specifically, at step 2324, the intelligent system 106 may diagnose itself by checking several parameters of the intelligent system 106 described herein, including, but not limited to, the sensor condition and/or output, the battery strength, the motor direction, the condition of the voltage reference that may be used in step 2500, and the presence or absence of user-input from buttons 502, 504. Moreover, at step 2324, a user of the article of footwear 100 may read data from the intelligent system 106 or perform other functions. In one embodiment, a special key is used to access the intelligent system 106. For example, armed with their own special keys, retailers could read certain data, manufacturers could read other data useful in, for example, preparing a failure report, and customers could be allowed to manually adjust the intelligent system 106 by, for example, moving the motor 132. Additionally or alternatively, the intelligent system 106 may be able to track or monitor the athletic performance of a wearer of the article of footwear 100, such as, for example, the distance traveled by the wearer, the wearer's pace, and/or the wearer's location. In such an embodiment, this information may be accessed at step 2324.

In one embodiment, the intelligent system 106 cycles through the steps of the method 2300 by following the directions of the arrows indicated in

1. A method for modifying a performance characteristic of an article of footwear during use, the method comprising the steps of: measuring a sensor signal from a sensor at least partially disposed within a sole of the article of footwear; determining whether the article of footwear has experienced a peak condition; upon determining that the article of footwear has experienced a peak condition, determining whether adjustment of the article of footwear is required; and upon determining that adjustment is required, adjusting a performance characteristic of the article of footwear.

2. The method of claim 1, wherein the peak condition is based on a change in state of the article of footwear as a result of an activity selected from the group consisting of a jump, a landing, a sprint, a turn, a cut, a push-off, and a stop.

3. The method of claim 2, wherein the change in state of the article is represented by at least one of absolute compression, rate of compression, frequency of compression, change in rate of compression, uneven compression, velocity, acceleration, jerk, and combinations thereof.

4. The method of claim 1, further comprising the step of automatically adjusting a threshold value for determining the peak condition.

5. The method of claim 4, further comprising the step of evaluating when the peak condition is over and automatically returning the threshold value to its previous setting.

6. The method of claim 1 further comprising the steps of: tracking a plurality of peak conditions experienced by the article of footwear; and automatically determining a new threshold value for determining whether the article of footwear has experienced a peak condition based on the plurality of peak conditions experienced.

7. The method of claim 1 further comprising the steps of: monitoring a state of the article of footwear; determining if the article is inactive; and upon determining that the article of footwear is inactive, enabling a sleep mode in the intelligent system.

8. The method of claim 7, wherein the step of monitoring the state of the article of footwear comprises sampling the sensor signal at set intervals.

9. The method of claim 8, wherein the determining step further comprises determining whether the sensor signal has remained substantially constant for a set time period.

10. The method of claim 7, wherein the step of enabling a sleep mode in the intelligent system comprises reducing power to at least one portion of the intelligent system.

11. The method of claim 7, further comprising reactivating the intelligent system upon an indication of use of the article of footwear.

12. The method of claim 11, wherein the indication of use is based on the article of footwear experiencing at least one of a vibration, a force, acceleration, velocity, a change in capacitance, and an increase in temperature within the shoe.

13. The method of claim 1 further comprising the steps of: receiving a user input related to an adjustment of the performance characteristic through a user interface; and adjusting an adjustable element at least partially disposed within the article of footwear in response to the user input.

14. The method of claim 13, wherein the user interface is selected from the group consisting of a capacitive user interface, a button, a switch, a slider, and a dial.

15. The method of claim 13, further comprising the step of providing an indication of a setting of the performance characteristic through an indicator.

16. The method of claim 15, wherein the indicator comprises at least one electro-luminescent element disposed on the article of footwear.

17. A method for modifying a performance characteristic of an article of footwear during use, the method comprising the steps of: measuring a sensor signal from a sensor at least partially disposed within a sole of the article of footwear; determining whether the article of footwear has experienced a desirable performance characteristic; upon determining that the article of footwear has not experienced the desirable performance characteristic, determining whether adjustment of the article of footwear is required; and upon determining that adjustment is required, adjusting a performance characteristic of the article of footwear during use.

18. A method for modifying a performance characteristic of an article of footwear during use, the method comprising the steps of: monitoring a sensor signal from a sensor at least partially disposed within a sole of the article of footwear; determining whether the article of footwear has experienced a desirable performance characteristic by at least analyzing the sensor signal to compare a measured performance characteristic to the desired performance characteristic; upon determining that the article of footwear has not experienced the desirable performance characteristic, determining whether adjustment of the article of footwear during use is required; and upon determining that adjustment is required, adjusting a performance characteristic of the article of footwear during use.