Footwear comprising rigid cage and variable padding element

Abstract

Articles of footwear comprising a rigid cage coupled to a sole and comprising a plurality of openings formed in the cage, and a padding element disposed under the rigid cage and comprising a plurality of projections. The projections can each comprise an exterior protrusion extending from the exterior surface of the padding element and disposed within one of the openings in the rigid cage. The projections can each comprise an interior protrusion extending from an interior surface of the padding element. In some embodiments, the size and shape of the interior and/or exterior protrusions can be based on data from a foot scan map.

1 . A method of making an article of footwear, the method comprising:
 obtaining a foot scan map comprising standard deviation values for variations in foot contour measured for a group of individuals;   forming a padding element, the padding element comprising:
 a base layer comprising an exterior surface and an interior surface disposed opposite the exterior surface; and 
 a plurality of projections, each of the plurality of projections comprising:
 an exterior protrusion extending from the exterior surface of the base layer; and 
 an interior protrusion extending from the interior surface of the base layer, 
 
 wherein at least one of a height or an effective diameter of respective interior protrusions varies based on the standard deviation values from the foot scan map; and 
   assembling the padding element with a rigid cage for the article of footwear such that the exterior protrusions of the plurality of projections are disposed within corresponding openings formed in the rigid cage.   
     
     
         2 . The method of  claim 1 , further comprising:
 isolating a rearfoot portion of the foot scan map,   wherein the at least one of a height or an effective diameter of the respective interior protrusions varies based on the standard deviation values of the isolated rearfoot portion of the foot scan map.   
     
     
         3 . The method of  claim 2 , wherein the padding element and the rigid cage are assembled in a rearfoot portion of the article of footwear corresponding to the isolated rearfoot portion of the foot scan map. 
     
     
         4 . The method of  claim 1 , further comprising flattening the foot scan map into a flat foot scan map. 
     
     
         5 . The method of  claim 4 , further comprising populating the flat foot scan map with graphical projections representing an arrangement of the plurality of projections on the base layer of the padding element. 
     
     
         6 . The method of  claim 4 , wherein a size or a shape of the base layer corresponds to a respective size or shape of the flat foot scan map. 
     
     
         7 . The method of  claim 4 , wherein the flat foot scan map is derived from a three-dimensional rendering of a virtual shoe last comprising the standard deviation values for variations in foot contour. 
     
     
         8 . The method of  claim 1 , wherein the group of individuals comprises a biometric characteristic, the biometric characteristic being one of heel striking, midfoot striking, forefoot striking, pronating, or supinating. 
     
     
         9 . The method of  claim 1 , wherein the padding element and the rigid cage are assembled such that the padding element is disposed between a textile layer of an upper of the article footwear and the rigid cage. 
     
     
         10 . The method of  claim 9 , wherein the padding element and the rigid cage are assembled such that at least a portion of an interior surface of the rigid cage overlaps an exterior surface of the textile layer of the upper. 
     
     
         11 . The method of  claim 9 , wherein the padding element and the rigid cage are assembled such that at least a portion of the textile layer overlaps an exterior surface of the rigid cage. 
     
     
         12 . The method of  claim 1 , wherein the padding element and the rigid cage are assembled such that one or more of the exterior protrusions extends exteriorly from one or more of the corresponding openings formed in the rigid cage. 
     
     
         13 . The method of  claim 1 , wherein the padding element and the rigid cage are assembled such that exterior-facing surfaces of the exterior protrusions are disposed interiorly from an exterior surface of the rigid cage. 
     
     
         14 . The method of  claim 1 , wherein the padding element and the rigid cage are assembled such that the interior protrusions define at least a portion of an interior surface of the article of footwear. 
     
     
         15 . The method of  claim 14 , wherein the plurality of projections is configured such that the projections are displaced along axes of the corresponding openings formed in the rigid cage when a wearer's foot contacts the interior protrusions. 
     
     
         16 . The method of  claim 1 , wherein the rigid cage is integrally formed with a sole of the article of footwear as a single piece. 
     
     
         17 . The method of  claim 1 , further comprising:
 assembling an additional padding element with an additional rigid cage for the article of footwear such that exterior protrusions of the additional padding element are disposed within corresponding openings formed in the additional rigid cage.   
     
     
         18 . The method of  claim 17 , wherein the rigid cage is disposed at least partially on a medial side of the article of footwear, and
 wherein the additional rigid cage is disposed at least partially on a lateral side of the article of footwear.   
     
     
         19 . The method of  claim 1 , wherein forming the padding element comprises additively manufacturing the base layer and the plurality of projections as a single piece. 
     
     
         20 . A method of making an article of footwear, the method comprising:
 forming a padding element, the padding element comprising:
 a base layer comprising an exterior surface and an interior surface disposed opposite the exterior surface; and 
 a plurality of projections, each of the plurality of projections comprising:
 an exterior protrusion extending from the exterior surface of the base layer; and 
 an interior protrusion extending from the interior surface of the base layer; and 
 
   assembling the padding element with a rigid cage for the article of footwear such that the exterior protrusions of the plurality of projections are disposed within corresponding openings formed in the rigid cage.