Sports boot buckle with segmented rack

Abstract

A lever and rack-type fastener assembly for sports footwear includes a lever assembly having a hooking member that is movably between an open position and a closed position for securing the footwear about the user's foot or ankle. A conformable segmented rack assembly is configured to engage the hook member. The segmented rack assembly includes a flexible cable, and a plurality of rack segments that is fixedly attached to the cable, wherein the cable provides a hinged joint between adjacent rack segments. Each of the rack segments includes a plurality of teeth. In some embodiments, an attachment plate clamps the rack members to the cable, in other embodiments, the rack members are formed with a crimpable channel for fixing the rack members to the cable.

The embodiments of the invention in which an exclusive property or privilege is claimed are defined as follows: 
     
         1 . A fastener assembly for sports footwear comprising:
 a lever assembly having a lever arm movable between an open position and a closed position, and a hooking member; and   a segmented rack assembly comprising a flexible cable having first and second spaced-apart portions, and a plurality of rack segments that are fixed to the cable first and second portions, each rack segment having a plurality of teeth, wherein the teeth are sized and shaped to releasably engage the hooking member;   wherein the plurality of rack segments are fixed serially on the cable such that adjacent rack segments are hingedly joined by the cable.   
     
     
         2 . The fastener assembly of  claim 1 , wherein the rack segments each comprise a toothed member defining a plurality of teeth that are configured to selectively engage the hooking member and an attachment plate that is attached to the toothed member to fixedly attach the rack segment to the flexible cable. 
     
     
         3 . The fastener assembly of  claim 2 , wherein at least one of the toothed member and the attachment plate define a pair of spaced-apart channels that are configured to engage the flexible cable. 
     
     
         4 . The fastener assembly of  claim 3 , wherein the attachment plate is attached to the toothed member with a threaded member that extends through an aperture in the attachment plate and threadably engages the toothed member. 
     
     
         5 . The fastener assembly of  claim 3 , wherein the toothed member further comprises a rivet portion that extends distally from the toothed member, and the attachment plate further comprises an aperture sized and configured to slidably receive the rivet portion, wherein the rivet portions fix the attachment plate to the toothed member. 
     
     
         6 . The fastener assembly of  claim 1 , wherein each of the plurality of rack segments is unitarily formed and comprise a toothed portion and a base portion, wherein the base portion comprises a crimpable channel portion that is sized and configured to receive the cable and to fix the rack segment to the flexible cable by crimping the crimpable channel portion. 
     
     
         7 . The fastener assembly of  claim 6 , wherein the crimpable channel portion further comprises a narrow inner channel portion that facilitates crimping the channel portion. 
     
     
         8 . The fastener assembly of  claim 6 , wherein the crimpable channel portion further comprises a plurality of gripping elements that engage the flexible cable. 
     
     
         9 . The fastener assembly of  claim 1 , wherein the flexible cable further comprises a U-shaped crimp connector that connects two portions of the flexible cable. 
     
     
         10 . The fastener assembly of  claim 9 , wherein the plurality of rack segments includes a distal rack segment having a distal channel portion that is configured to receive the U-shaped crimp connector. 
     
     
         11 . The fastener assembly of  claim 1 , wherein the plurality of rack segments is fixed to the cable such that adjacent rack segments are separated by a gap. 
     
     
         12 . The fastener assembly of  claim 1 , wherein at least one of the plurality of rack segments defines a convex end portion, and at least one of the plurality of rack segments defines a concave end portion that is sized and shaped to receive the convex end portion. 
     
     
         13 . The fastener assembly of  claim 12 , wherein the convex end portion is cylindrical. 
     
     
         14 . The fastener assembly of  claim 1 , wherein the segmented rack assembly comprises at least three rack segments. 
     
     
         15 . The fastener assembly of  claim 1 , wherein the toothed members are formed of aluminum. 
     
     
         16 . A segmented rack assembly for a sporting boot fastener assembly comprising:
 a flexible cable having first and second spaced-apart portions; and   at least three rack segments, wherein each rack segment is fixed to the cable first and second portions, each rack segment having a plurality of spaced-apart teeth that are sized and configured to releasably engage a hook member;   wherein the at least three rack segments are fixed to the flexible cable such that adjacent rack segments are hingedly connect by the cable.   
     
     
         17 . The segmented rack assembly of  claim 16 , wherein the at least three rack segments each comprise a toothed portion and an attachment plate, and wherein each rack assembly is attached to the flexible cable by clamping the flexible cable between the toothed portion and the attachment plate.