Patent Application
20250194747
The described embodiments generally relate to articles of footwear. More particularly, described embodiments relate to footwear comprising a rigid cage and padding element assembly that provides desired support and cushioning for a wearer.
The human foot is a complex and remarkable piece of machinery, capable of withstanding and dissipating many loading forces. The natural padding of fat at the heel and forefoot, as well as the numerous joints within the foot help to dissipate and align those loads to the direction of travel. Although the human foot possess natural dampening and alignment characteristics, the foot alone is incapable of effectively overcoming and aligning the many forces encountered during everyday activity. Unless an individual is wearing shoes that provide proper movement and support, the soreness and fatigue associated with every day activity is more acute, and its onset may be accelerated.
Individuals are often concerned with the amount of cushion and support an article of footwear provides. This is true for articles of footwear worn for non-performance activities, such as a leisurely stroll, and for performance activities, such as running and cutting, because throughout the course of an average day, the feet and legs of an individual are subjected to substantial loading forces requiring both impact and torque protection. When an article of footwear contacts a surface, considerable forces may act on the article of footwear and, correspondingly, the wearer's foot. The upper of an article of footwear functions, in part, to provide cushioning to the wearer's foot and to protect it from these forces.
Proper footwear should be durable, comfortable, and provide other beneficial characteristics for an individual. Therefore, a continuing need exists for innovations in footwear.
A first embodiment (1) of the present application is directed to an article of footwear comprising a sole; and an upper coupled to the sole along a bite line, the upper comprising a rigid cage coupled to the sole along at least a portion of the bite line and comprising a plurality of openings formed in the cage, a padding element disposed under the rigid cage and comprising a base layer comprising an exterior surface facing an interior surface of the rigid cage 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 disposed within one of the openings in the rigid cage, and an interior protrusion extending from the interior surface of the base layer.
In a second embodiment (2), the rigid cage according to the first embodiment (1) wraps around a rearfoot portion of the article of footwear to form a heel cage.
In a third embodiment (3), the rigid cage according to the first embodiment (1) or the second embodiment (2) is integrally formed with the sole at the bite line.
In a fourth embodiment (4), the padding element of any one of embodiments (1)-(3) comprises an elastomeric foam.
In a fifth embodiment (5), at least some of the plurality of exterior protrusions according to any one of embodiments (1)-(4) extend outward from the openings of the rigid cage.
In a sixth embodiment (6), the plurality of interior protrusions according to any one of embodiments (1)-(5) comprise a height ranging from 1 mm to 6 mm.
In a seventh embodiment (7), the plurality of interior protrusions according to any one of embodiments (1)-(5) comprise a height, and the height of respective interior protrusions varies on the interior surface of the base layer.
In an eighth embodiment (8), a variation between the height of a shortest interior protrusion and the height of a tallest interior protrusion according to the seventh embodiment (7) is at least 2 mm.
In a ninth embodiment (9), the height of respective interior protrusions according to the seventh embodiment (7) varies based on data from a foot scan map, the data comprising standard deviation values for variations in foot contour measured for a group of individuals.
In a tenth embodiment (10), the plurality of interior protrusions according to any one of embodiments (1)-(9) comprise an effective diameter ranging from 2 mm to 30 mm.
In an eleventh embodiment (11), the plurality of interior protrusions according to any one of embodiments (1)-(9) comprise an effective diameter, and the effective diameter varies on the interior surface of the base layer.
In a twelfth embodiment (12), a variation between the effective diameter of a smallest interior protrusion and the effective diameter of a largest interior protrusion according to the eleventh embodiment (11) is at least 2 mm.
In a thirteenth embodiment (13), the effective diameter of respective interior protrusions according to the eleventh embodiment (11) varies based on data from a foot scan map, the data comprising standard deviation values for variations in foot contour measured for a group of individuals.
In a fourteenth embodiment (14), the plurality of exterior protrusions according to any one of embodiments (1)-(13) comprise a height, and the height of respective exterior protrusions varies on the exterior surface of the base layer.
In a fifteenth embodiment (15), a first plurality of the exterior protrusions according to the fourteenth embodiment (14) comprise a height that extends outward from an exterior surface of the rigid cage, and a second plurality of the exterior protrusions according to the fourteenth embodiment (14) comprise a height disposed below the exterior surface of the rigid cage.
In a sixteenth embodiment (16), the plurality of openings formed in the rigid cage according to any one of embodiments (1)-(15) comprise an effective diameter ranging from 1 mm to 30 mm.
In a seventeenth embodiment (17), the plurality of openings formed in the rigid cage according to any one of embodiments (1)-(15) comprise an effective diameter, and the effective diameter varies on the rigid cage.
In an eighteenth embodiment (18), the base layer and the plurality of projections according to any one of embodiments (1)-(17) are integrally formed as a single piece.
In a nineteenth embodiment (19), the upper according to any one of embodiments (1)-(18) comprises a textile layer coupled to the rigid cage and the padding element.
A twentieth embodiment (20) of the present application is directed to 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.
The present invention(s) will now be described in detail with reference to embodiments thereof as illustrated in the accompanying drawings. References to “some embodiments”, “one embodiment”, “an embodiment”, “an exemplary embodiment”, etc., indicate that the embodiment described can comprise a particular feature, structure, or characteristic, but every embodiment may not necessarily include the particular feature, structure, or characteristic. Moreover, such phrases are not necessarily referring to the same embodiment. Further, when a particular feature, structure, or characteristic is described in connection with an embodiment, it is submitted that it is within the knowledge of one skilled in the art to affect such feature, structure, or characteristic in connection with other embodiments whether or not explicitly described.
The indefinite articles “a,” “an,” and “the” include plural referents unless clearly contradicted or the context clearly dictates otherwise.
The term “comprising” is an open-ended transitional phrase. A list of elements following the transitional phrase “comprising” is a non-exclusive list, such that elements in addition to those specifically recited in the list can also be present.
As used herein, unless specified otherwise, references to “first,” “second,” “third,” “fourth,” etc. are not intended to denote order, or that an earlier-numbered feature is required for a later-numbered feature. Also, unless specified otherwise, the use of “first,” “second,” “third,” “fourth,” etc. does not necessarily mean that the “first,” “second,” “third,” “fourth,” etc. features have different properties or values.
Articles of footwear, and components thereof, described herein can provide unique support, cushioning, and/or aesthetics. In particular embodiments, uppers described herein comprise a rigid cage configured to provide desired support to at least a portion of an article of footwear, for example a heel region or a midfoot region. The rigid cage can comprise openings configured to receive protrusions on a padding element. In some embodiments, characteristics of the openings can be based on foot scan data, which can facilitate targeted support and comfort characteristics for rigid cage.
Uppers described herein can also comprise a padding element designed to account for different foot contours and shapes. The padding elements can provide targeted cushioning and/or support to improve the fit of an upper on a wearer's foot. In particular embodiments, the padding element can comprise projections having interior and/or exterior protrusions with characteristics based on foot scan data, which can provide targeted support and comfort characteristics for the padding element.
Together, the padding element and rigid cage can interface with each other to provide desired support and/or cushioning characteristics. When assembled, the exterior protrusions of the padding element can extend into openings on the rigid cage. This interface between the padding element and rigid cage can allow the padding element to push through the openings, which can help achieve an even pressure distribution on a wearer's foot. This interface, along with characteristics of the interior and/or exterior protrusions on the padding element described herein, can achieve even pressure distribution and cushioning properties for various foot shapes and contours. The pressure distribution and cushioning created by the unique padding elements and rigid cages described herein can reduce or prevent discomfort for a wearer.
What is more, the padding element, the rigid cage, and the interface between the two as described herein can provide improved fit and lock down across various foot shapes (for example, heel shapes) while not hindering lock in on dynamic movements. The flexibility and cushion provided the padding element, and the rigidity provided by the rigid cage provide a unique combination of support, cushioning, fit, and lock in. This unique combination of features can provide a comfortable and supportive article of footwear for use in a variety of situations, including non-performance activities and performance activities, such as running or sport activities.
In some embodiments, rigid cage 124 can be coupled to sole 130 along at least a portion of bite line 140. In some embodiments, rigid cage 124 can be manufactured separately from and attached to sole 130 (for example, by adhesive bonding, mechanical bonding, stitching, or welding) at bite line 140. In some embodiments, as shown for example in
Article of footwear 100 can comprise a forefoot end 102, a rearfoot end 104, a medial side 106, and a lateral side 108 opposite medial side 106. Also, as shown for example in
In some embodiments, rigid cage 124 can wrap around rearfoot portion 114 of an article of footwear 100 to form a heel cage 150. In some embodiments, rigid cage 124 can additionally or alternative wrap around forefoot portion 110 of article of footwear 100. In some embodiments, rigid cage 124 can wrap around forefoot portion 110, midfoot portion 112, and rearfoot portion 114 of article of footwear 100.
Upper 120 and sole 130 can be configured for a specific type of footwear, comprising, but not limited to, a cleat (e.g., a baseball cleat, a soccer cleat, or a football cleat), a basketball shoe, a running shoe, a hiking shoe, a water shoe, a training shoe, a fitness shoe, a dancing shoe, a biking shoe, a tennis shoe, a boot, a walking shoe, a casual shoe, or a dress shoe. In some embodiments, sole 130 can comprise traction elements, for example cleats 132 as shown in
In some embodiments, upper 120 can comprise a textile layer 122. Textile layer 122 can be coupled to other components of footwear 100, for example, sole 130, a rigid cage 124, and/or a padding element 126, by any suitable attachment technique (for example, adhesive bonding, mechanical bonding, heat bonding, stitching, or a combination thereof). In some embodiments, textile layer 122 can comprise one or more lace structures for receiving a shoe lace. In some embodiments, textile layer 122 can be coupled to rigid cage 124 and padding element 126.
In some embodiments, textile layer 122 can be coupled to an interior surface 222 of rigid cage 124 such that at least a portion of rigid cage 124 overlaps an exterior surface of textile layer 122. In some embodiments, textile layer 122 can be coupled to an exterior surface 223 of rigid cage 124 such that at least a portion of textile layer 122 overlaps exterior surface 223 of rigid cage 124. In some embodiments, at least a portion of textile layer 122 can be disposed between interior surface 222 of rigid cage 124 and an exterior surface 220 of padding element 126. In such embodiments, at least a portion of textile layer 122 can be coupled to interior surface 222 of rigid cage 124 and exterior surface 220 of padding element 126. In some embodiments, as shown for example in
Suitable materials for textile layer 122 include, but are not limited to, a non-woven fabric, a woven fabric, knitted fabric material, natural leather, or synthetic leather. In some embodiments, textile layer 122, or a piece of material defining textile layer 122 can comprise a foam material. Exemplary textile materials for textile layer 122 comprise, but are not limited to, thermoplastic polyurethane (TPU), polyester, polyamide, polyethylene (PE), PE foam, polyurethane (PU) foam, nylon, ultra-high molecular weight polyethylene (for example, DYNEEMA® (a type of ultra-high molecular weight polyethylene)), carbon fiber, KEVLAR® (a type of para-aramid), synthetic spider silk, cotton, wool, natural or artificial silk, polyethersulfone (PES), ELASTAN® (a polyether-polyurea copolymer), or a blend of two or more of these materials. In some embodiments, textile layer 122, or a piece of material defining textile layer 122, can comprise a polymeric sheet or film, for example, a TPU sheet or film. In some embodiments, textile layer 122, or a piece of material defining textile layer 122, can comprise a mesh material.
Rigid cage 124 comprises a rigid material. Suitable rigid materials for rigid cage 124 include, but are not limited to, thermoplastic polyurethane (TPU), expanded polyurethane (EPU), ethylene-vinyl acetate (EVA), nylon, and fiber composite materials, for example carbon fiber and fiber glass composites. In some embodiments, rigid cage 124 can comprise a rigid material having a durometer Shore hardness of greater than or equal to 35D. In some embodiments, rigid cage 124 can comprise a rigid material having a durometer Shore hardness of greater than or equal to 60D. In some embodiments, rigid cage 124 can comprise a rigid material having a rigidity greater than the rigidity of the material of padding element 126. In some embodiments, rigid cage 124 can comprise a rigid material having a Shore hardness greater than the Shore hardness of the material of padding element 126.
Rigid cage 124 comprises a plurality of openings 202 formed in cage 124. Openings 202 are through openings extending from interior surface 222 of rigid cage 124 to exterior surface 223 of rigid cage 124. In some embodiments, openings 202 can be arranged in a regular, repeated pattern. In some embodiments, openings 202 can be arranged in straight lines. In some embodiments, openings 202 can be arranged along slanted lines or curved lines.
Upper 120 can also comprise padding element 126 disposed under rigid cage 124. In some embodiments, padding element 126 can be coupled to interior surface 222 of rigid cage 124. In some embodiments, exterior surface 220 of padding element 126 can be coupled to interior surface 222 of rigid cage 124. Padding element 126 can be coupled to interior surface 222 of rigid cage 124 using any suitable attachment technique, including but not limited to, adhesive bonding, mechanical bonding, heat bonding, stitching, or a combination thereof.
Padding element 126 can comprise a soft material. In some embodiments, padding element 126 can comprise an elastomeric foam or an elastomeric polymer. Suitable soft materials for padding element 126 include, but are not limited to, a polyurethane, ethyl vinyl acetate (EVA), a polyethylene, a rubber (for example, styrene butadiene rubber), a latex, Neoprene (polychloroprene), a polyether, and a foam comprising any of these materials. In some embodiments, padding element 126 can comprise a soft material having a durometer Shore hardness of less than or equal to 40C. In some embodiments, padding element 126 can comprise a soft material having a durometer Shore hardness of less than or equal to 40C and greater than or equal to 15C.
As shown for example in
In some embodiments, base layer 210 and projections 214 can be integrally formed as a single piece. For example, in some embodiments, base layer 210 and projections 214 can be integrally molded or additively manufactured as a single piece. In some embodiments, projections 214, or portions thereof, including interior protrusions 216 and exterior protrusions 218, can be manufactured separately from and attached to base layer 210 (for example, by adhesive bonding, mechanical bonding, stitching, welding).
As shown for example in
In some embodiments, when padding element 126 is assembled with rigid cage 124, some or all of exterior protrusions 218 can be disposed within openings 202 and not extend through openings 202. In such embodiments, a top surface 619 of exterior protrusions 218 can be disposed inward from exterior surface 223 of rigid cage 124.
In some embodiments, when padding element 126 is assembled with rigid cage 124, some or all of exterior protrusions 218 can be flush with openings 202 and not extend outward from openings 202. In such embodiments, a top surface 619 of exterior protrusions 218 can be flush with exterior surface 223 of rigid cage 124.
In some embodiments the arrangement of a plurality of projections 214 can be identical on both sides of base layer 210. In such embodiments, respective interior protrusions 216 of projections 214 on interior surface 224 can correspond in position to respective exterior protrusions 218 on exterior surface 220. In some embodiments, the arrangement of interior protrusions 216 on interior surface 224 can differ relative to the arrangement of exterior protrusions 218 on exterior surface 220.
In some embodiments, as shown for example in
In some embodiments, as shown for example in
The term “effective diameter” is used to describe the size of a component (for example, a protrusion or opening), but this term should not be interpreted as requiring the component to have a circular diameter or shape. Instead, the component can have a non-circular shape, and in such embodiments, the term “effective diameter” is intended to refer to the maximum cross-sectional dimension of the shape. For example, the “effective diameter” of a component having an elliptical cross-sectional shape would be the length of the major axis of the elliptical shape. For a component having an effective diameter that varies along its depth or height, the effective diameter is the largest effective diameter.
In some embodiments, interior protrusions 216 can each comprise a height 600 ranging from 1 mm (millimeters) to 15 mm. In some embodiments, interior protrusions 216 can each comprise a height 600 ranging from 1 mm to 10 mm. In some embodiments, interior protrusions 216 can each comprise a height 600 ranging from 1 mm to 6 mm. In some embodiments, interior protrusions 216 can each comprise a height 600 ranging from 2 mm to 4 mm.
In some embodiments, a plurality of interior protrusions 216 can comprise a height 600, and the height 600 of respective interior protrusions (for example, first height 600a and second height 600b) can vary on interior surface 224 of base layer 210. In some embodiments, a variation between the height 600 of a shortest interior protrusion 216 (for example, height 600b) and the height 600 of a tallest interior protrusion 216 (for example, height 600a) can be at least 12 mm. In such embodiments, height 600a can be at least 12 mm greater than height 600b. In some embodiments, a variation between the height 600 of a shortest interior protrusion 216 (for example, height 600b) and the height 600 of a tallest interior protrusion 216 (for example, height 600a) can be at least 8 mm. In such embodiments, height 600a can be at least 8 mm greater than height 600b. In some embodiments, a variation between the height 600 of a shortest interior protrusion 216 (for example, height 600b) and the height 600 of a tallest interior protrusion 216 (for example, height 600a) can be at least 2 mm. In such embodiments, height 600a can be at least 2 mm greater than height 600b.
In some embodiments, height 600 of respective interior protrusions 216 can vary based on data from a foot scan map, for example map 700, such that the height of respective interior protrusions 216 (for example, first height 600a and second height 600b) varies based on data from the foot scan map.
In some embodiments, exterior protrusions 218 can each comprise a height 610 ranging from 1 mm to 15 mm. In some embodiments, exterior protrusions 218 can each comprise a height 610 ranging from 1 mm to 10 mm. In some embodiments, exterior protrusions 218 can each comprise a height 610 ranging from 1 mm to 6 mm. In some embodiments, exterior protrusions 218 can each comprise a height 610 ranging from 2 mm to 4 mm.
In some embodiments, a plurality of exterior protrusions 218 can comprise a height 610, and the height 610 of respective interior protrusions (for example, first height 610a and second height 610b) can vary on exterior surface 220 of base layer 210. In some embodiments, a variation between the height 610 of a shortest exterior protrusion 218 (for example, height 610b) and the height 610 of a tallest exterior protrusion 218 (for example, height 610a) can be at least 12 mm. In such embodiments, height 610a can be at least 12 mm greater than height 610b. In some embodiments, a variation between the height 610 of a shortest exterior protrusion 218 (for example, height 610b) and the height 610 of a tallest exterior protrusion 218 (for example, height 610a) can be at least 8 mm. In such embodiments, height 610a can be at least 8 mm greater than height 610b. In some embodiments, a variation between the height 610 of a shortest exterior protrusion 218 (for example, height 610b) and the height 610 of a tallest exterior protrusion 218 (for example, height 610a) can be at least 2 mm. In such embodiments, height 610a can be at least 2 mm greater than height 610b.
In some embodiments, height 610 of respective exterior protrusions 218 can vary based on data from a foot scan map, for example map 700, such that the height of respective exterior protrusions 218 (for example, first height 610a and second height 610b) varies based on data from the foot scan map.
In some embodiments, a first plurality of exterior protrusions 218 can comprise a height 610 that extends outward from exterior surface 223 of rigid cage 124, and a second plurality of exterior protrusions 218 can comprise a height 610 disposed below exterior surface 223 of rigid cage 124. In such embodiments, a top surface 619 of the first plurality of exterior protrusions 218 can be disposed outward from exterior surface 223 of rigid cage 124, and top surface 619 of the second plurality of exterior protrusions 218 can be disposed inward from exterior surface 223 of rigid cage 124.
In some embodiments, interior protrusions 216 can each comprise an effective diameter 620 ranging from 2 mm to 30 mm. In some embodiments, interior protrusions 216 can each comprise an effective diameter 620 ranging from 5 mm to 30 mm, from 10 mm to 30 mm, from 5 mm to 25 mm, or from 5 mm to 20 mm.
In some embodiments, a plurality of interior protrusions 216 can comprise an effective diameter 620, and the effective diameter 620 of respective interior protrusions 216 (for example, first effective diameter 620a and second effective diameter 620b) can vary on interior surface 224 of base layer 210. In some embodiments, a variation between the effective diameter 620 of a narrowest interior protrusion 216 (for example, effective diameter 620b) and the effective diameter 620 of a widest interior protrusion 216 (for example, effective diameter 620a) can be at least 10 mm. In such embodiments, effective diameter 620a can be at least 10 mm greater than effective diameter 620b. In some embodiments, a variation between the effective diameter 620 of a narrowest interior protrusion 216 (for example, effective diameter 620b) and the effective diameter 620 of a widest interior protrusion 216 (for example, effective diameter 620a) can be at least 2 mm. In such embodiments, effective diameter 620a can be at least 2 mm greater than effective diameter 620b.
In some embodiments, effective diameter 620 of respective interior protrusions 216 can vary based on data from a foot scan map, for example map 700, such that the effective diameter of respective interior protrusions 216 (for example, first effective diameter 620a and second effective diameter 620b) varies based on data from the foot scan map.
In some embodiments, exterior protrusions 218 can each comprise an effective diameter 630 ranging from 2 mm to 30 mm. In some embodiments, exterior protrusions 218 can each comprise an effective diameter 630 ranging from 5 mm to 30 mm, from 10 mm to 30 mm, from 5 mm to 25 mm, or from 5 mm to 20 mm.
In some embodiments, a plurality of exterior protrusions 218 can comprise an effective diameter 630, and the effective diameter 630 of respective exterior protrusions 218 (for example, first effective diameter 630a and second effective diameter 630b) can vary on exterior surface 220 of base layer 210. In some embodiments, a variation between the effective diameter 630 of a narrowest exterior protrusion 218 (for example, effective diameter 630b) and the effective diameter 630 of a widest exterior protrusion 218 (for example, effective diameter 630a) can be at least 10 mm. In such embodiments, effective diameter 630a can be at least 10 mm greater than effective diameter 630b. In some embodiments, a variation between the effective diameter 630 of a narrowest exterior protrusion 218 (for example, effective diameter 630b) and the effective diameter 630 of a widest exterior protrusion 218 (for example, effective diameter 630a) can be at least 2 mm. In such embodiments, effective diameter 630a can be at least 2 mm greater than effective diameter 630b.
In some embodiments, the effective diameter 630 of respective exterior protrusions 218 can vary based on data from a foot scan map, for example map 700, such that the effective diameter of respective exterior protrusions 218 (for example, first effective diameter 630a and second effective diameter 630b) varies based on data from the foot scan map.
In some embodiments, openings 202 in rigid cage 124 can comprise an effective diameter 640 ranging from 1 mm to 30 mm. In some embodiments, openings 202 in rigid cage 124 can comprise an effective diameter 640 ranging from 2 mm to 30 mm, from 5 mm to 30, from 10 mm to 30 mm, from 1 mm to 25 mm, or from 1 mm to 20 mm. In some embodiments, a plurality of openings 202 can comprise an effective diameter 640 and the effective diameter 640 of respective openings 202 can vary on rigid cage 124. In some embodiments, a variation between the effective diameter 640 of a narrowest opening 202 and the effective diameter 640 of a widest opening 202 can be at least 2 mm.
In some embodiments, effective diameter 640 of respective openings 202 can vary based on data from a foot scan map, for example map 700, such that effective diameter 640 of respective openings 202 varies based on data from the foot scan map.
In some embodiments, a plurality of projections 214 can be sized and shaped identically on either side of base layer 210. In such embodiments, interior protrusions 216 on interior surface 224 can be identical in height and effective diameter to corresponding exterior protrusions 218 on exterior surface 220. In some embodiments, a plurality of interior protrusions 216 can have different heights and/or effective diameters from those of corresponding exterior protrusions 218.
In some embodiments, adjacent exterior protrusions 218 can be positioned at least 3 mm from one another. In such embodiments, a width 650 between adjacent openings 202 can be at least 3 mm. Sufficient spacing between adjacent exterior protrusions 218 and openings 202 can serve to ensure rigid cage 124 provides desired strength and support for a wearer.
As shown for example in
It is to be appreciated that the shape of openings 202, interior protrusions 216, and exterior protrusions 218 can vary. As shown for example in
In some embodiments, upper 120 and projections 214 can be arranged, shaped, and/or sized to provide a desired combination of cushioning, comfort, support, and/or stability to article of footwear 100 based a wearer's desired fit or anatomical needs (for example, the contour of the wearer's foot).
In some embodiments, the arrangement and dimensions (shape and size) of projections 214 can be based on data from a foot scan map 700. In some embodiments, the data of foot scan map 700 can comprise standard deviation values for variations in foot contour measured for a group of individuals. In some embodiments, the standard deviation values for variations in foot contour can be variations in a lateral dimension perpendicular to the perimeter foot contour for each individual in the group of individuals. For example, as illustrated in
Standard deviation values for variations in foot contour measured for a group of individuals in map 700 are indicative of how much variation is present in foot shape for the group of individuals. For example, map 700 shows that the shape of the individuals' upper ankle region had the most variation, meaning that the individuals' upper ankles had significantly different shapes and contours. As another example, map 700 shows that the shape of the individuals' bottom heel region had the lowest variation, meaning that the shape and contour of the individuals' bottom heel region was most consistent. In other words, foot scan map 700 can show anatomical variance in a group of individuals, for example in the structure and positioning of the individuals' ankles, Achilles' heels, toes, etc.
A foot scan map 700 can be created by (i) scanning the feet of a group of individuals and using a computer program to align each scan at a particular point (for example, transversally and at the heel points) and (ii) calculating the standard deviation values for variations in foot contour at various points on the aligned scans. The foot scans can be collected using, for example, a Tiger 3D CAD/CAM Scanner system, and modeling software such as GRASSHOPPER™ and RHINO® 3D can be used to align the scans and calculate the standard deviations in contour.
In some embodiments, foot scan map 700 can comprise standard deviation values for variations in foot contour measured for a group of at least 50 individuals. In some embodiments, foot scan map 700 comprise standard deviation values for variations in foot contour measured for a group of individuals having a similar biometric characteristic. Exemplary biometric characteristics include, but are not limited to, a heel striker, a midfoot striker, a forefoot striker, a pronator, a supinator, a gender, a shoe size range, a height range, and a weight range.
First, in step 801 illustrated in
In step 802 illustrated in
In step 803 illustrated in
In some embodiments, after step 803, portion 810 can be a flattened into a flat map 820 as shown in step 804 illustrated in
In step 805 illustrated in
Graphical projections 814 can represent the arrangement, size, and shape of projections 214 on padding element 126. Graphical projections 814 can be populated using, for example, graphics software, such as Vectoraster, ADOBE ILLUSTRATOR®, Blender, or Gravity Sketch software. In some embodiments, modeling software such as GRASSHOPPER™ and RHINO® 3D can additionally or alternately be used. Various design constraints, for example, a shape parameter, a size parameter, a material parameter, or a combination therefore can be input into the software used to populate the graphical projections 814. The software can comprise an algorithm that selects the arrangement, size, and shape of projections 814 based on at least the standard deviation values from map 700 and the inputted design constraints. In some embodiments, at least one of the density, size (height), and shape (effective diameter) of projections 814 can increase as the standard deviation values from map 700 increase.
After populating projections 814, padding element 126 comprising base layer 210 and projections 214 can be formed based on at least flat map 820 (or portion 810) and projections 814. The arrangement, size, and shape of projections 214 (including the arrangement, size, and shape of interior protrusions 216 and/or exterior protrusions 218) can be based on projections 814.
In some embodiments, at least one of height 600 or effective diameter 620 of respective interior protrusions 216 can vary based on the standard deviation values from map 700. For example, at least one of height 600 and effective diameter 620 of respective interior protrusions 216 can increase as the standard deviation values from map 700 increase. In such embodiments, the height 600 and/or effective diameter 620 of respective interior protrusions 216 can be based on corresponding projections 814 populated in step 805.
In some embodiments, at least one of height 610 or effective diameter 630 of respective exterior protrusions 218 can vary based on the standard deviation values from map 700. For example, at least one of height 610 and effective diameter 630 of respective exterior protrusions 218 can increase as the standard deviation values from map 700 increase. In such embodiments, the height 610 and/or effective diameter 630 of respective exterior protrusions 218 can be based on corresponding projections 814 populated in step 805.
In some embodiments, the perimeter size and shape of base layer 210 can be based on the size and shape of flat map 820, or portion 810.
After forming padding element 126 based on a foot scan map (for example, map 700), padding element 126 can be assembled with rigid cage 124 for footwear 100 such that exterior protrusions 218 of the plurality of projections 214 are disposed within corresponding openings 202 formed in rigid cage 124.
As shown in
In some embodiments, as shown in
In some embodiments, as shown in
In some embodiments, as shown in
In some embodiments, as shown in
In some embodiments, as shown in
Where a range of numerical values comprising upper and lower values is recited herein, unless otherwise stated in specific circumstances, the range is intended to include the endpoints thereof, and all integers and fractions within the range. It is not intended that the disclosure or claims be limited to the specific values recited when defining a range. Further, when an amount, concentration, or other value or parameter is given as a range, one or more ranges, or as list of upper values and lower values, this is to be understood as specifically disclosing all ranges formed from any pair of any upper range limit or value and any lower range limit or value, regardless of whether such pairs are separately disclosed.
It is to be appreciated that the Detailed Description section, and not the Summary and Abstract sections, is intended to be used to interpret the claims. The Summary and Abstract sections may set forth one or more but not all exemplary embodiments of the present invention(s) as contemplated by the inventor(s), and thus, are not intended to limit the present invention(s) and the appended claims in any way.
The foregoing description of the specific embodiments will so fully reveal the general nature of the invention(s) that others can, by applying knowledge within the skill of the art, readily modify and/or adapt for various applications such specific embodiments, without undue experimentation, without departing from the general concept of the present invention(s). Therefore, such adaptations and modifications are intended to be within the meaning and range of equivalents of the disclosed embodiments, based on the teaching and guidance presented herein. It is to be understood that the phraseology or terminology herein is for the purpose of description and not of limitation, such that the terminology or phraseology of the present specification is to be interpreted by the skilled artisan in light of the teachings and guidance.
The breadth and scope of the present invention(s) should not be limited by any of the above-described exemplary embodiments, but should be defined only in accordance with the following claims and their equivalents.
