Footwear with padding and midsole structures and the method of making the same

Abstract

A method of manufacturing an article of footwear includes positioning an upper on a last that defines openings connected by one or more channels in the last, injecting a material through the one or more channels in the last, and forming a structure on the upper with the material.

What is claimed is: 
     
         1 . An article of footwear comprising:
 a base layer comprising a textile material and forming an upper; and   a footwear component disposed on the base layer, the footwear component formed of an injected polymeric material that adheres to the base layer as the injected polymeric material cures.   
     
     
         2 . The article of footwear of  claim 1 , wherein the footwear component comprises an ankle padding. 
     
     
         3 . The article of footwear of  claim 1 , wherein the footwear component comprises a midfoot support. 
     
     
         4 . The article of footwear of  claim 1 , wherein the footwear component comprises a midsole. 
     
     
         5 . The article of footwear of  claim 4 , wherein the midsole has a dual density. 
     
     
         6 . The article of footwear of  claim 1 , wherein the footwear component is disposed on an exterior side of the base layer. 
     
     
         7 . The article of footwear of  claim 1 , wherein the footwear component is disposed on an interior side of the base layer. 
     
     
         8 . The article of footwear of  claim 1 , further comprising one or more additional footwear components disposed on the base layer and formed of the injected polymeric material that adheres to the base layer as the injected polymeric material cures. 
     
     
         9 . The article of footwear of  claim 8 , wherein at least one footwear component is disposed on an interior side of the base layer and at least one footwear component is disposed on an exterior side of the base layer. 
     
     
         10 . The article of footwear of  claim 1 , wherein the textile material comprises a knitted textile. 
     
     
         11 . The article of footwear of  claim 1 , wherein the injected polymer material comprises a polyurethane foam. 
     
     
         12 . An article of footwear comprising:
 an upper; and   a footwear component disposed on the upper, the footwear component formed of an injected polymeric material,   wherein the footwear component is shaped based on a pattern disposed on an outer surface of a last, wherein the pattern comprises an engraved feature or an embossed feature.   
     
     
         13 . The article of footwear of  claim 12 , wherein the pattern comprises the engraved feature, and wherein the footwear component comprises padding disposed on an interior of the upper. 
     
     
         14 . The article of footwear of  claim 12 , wherein the pattern comprises the embossed feature, and wherein the footwear component forms a haptic texture. 
     
     
         15 . The article of footwear of  claim 12 , wherein the pattern comprises the engraved feature and the embossed feature. 
     
     
         16 . The article of footwear of  claim 15 , wherein the footwear component is disposed on an exterior of the upper. 
     
     
         17 . The article of footwear of  claim 12 , wherein the upper comprises a textile material. 
     
     
         18 . The article of footwear of  claim 12 , wherein the upper comprises leather. 
     
     
         19 . An article of footwear comprising:
 an upper comprising a knitted textile; and   an ankle padding footwear component disposed on the upper, wherein the ankle padding footwear component is disposed on an interior of the knitted textile.   
     
     
         20 . The article of footwear of  claim 19 , wherein the ankle padding is formed of an injected polymeric material that adheres to the upper as the injected polymeric material cures.