U.S. patent application number 12/186017 was filed with the patent office on 2010-02-11 for printed sole for a shoe and method of making.
Invention is credited to Gregory Ross Leedy.
Application Number | 20100031535 12/186017 |
Document ID | / |
Family ID | 41278420 |
Filed Date | 2010-02-11 |
United States Patent
Application |
20100031535 |
Kind Code |
A1 |
Leedy; Gregory Ross |
February 11, 2010 |
PRINTED SOLE FOR A SHOE AND METHOD OF MAKING
Abstract
A method of forming a sole element for an article of footwear
includes obtaining a partially-cured substrate having a first
surface and an opposed surface opposite the first surface and
applying one or more graphic elements to the first surface to
create a decorated substrate. The method further includes placing
the decorated partially-cured substrate into a mold for a sole
element and curing the decorated substrate. During curing, at least
a portion of each of the first surface and the opposed surface may
contact the mold. Also, during curing, the decorated substrate may
substantially fill the mold. Articles of footwear, including sole
elements formed by the disclosed methods and uppers configured to
retain the sole element to a user's foot, are provided.
Inventors: |
Leedy; Gregory Ross;
(Portland, OR) |
Correspondence
Address: |
BANNER & WITCOFF, LTD.
28 STATE STREET, SUITE 1800
BOSTON
MA
02109-1701
US
|
Family ID: |
41278420 |
Appl. No.: |
12/186017 |
Filed: |
August 5, 2008 |
Current U.S.
Class: |
36/103 ; 12/146B;
36/25R; 36/45 |
Current CPC
Class: |
B29D 35/142 20130101;
B29D 35/0054 20130101; B29C 43/20 20130101; B29L 2031/722 20130101;
B29C 43/145 20130101; B29C 2043/023 20130101; A43B 23/24 20130101;
B29K 2995/003 20130101; A43B 1/0027 20130101; A43B 3/0078 20130101;
B29C 43/021 20130101; A43B 13/223 20130101; B29K 2021/00 20130101;
B29L 2031/504 20130101 |
Class at
Publication: |
36/103 ; 36/25.R;
36/45; 12/146.B |
International
Class: |
A43B 13/00 20060101
A43B013/00; A43B 23/00 20060101 A43B023/00; A43D 8/00 20060101
A43D008/00 |
Claims
1. A method of forming a sole element for an article of footwear,
comprising: obtaining a partially-cured substrate having a first
surface and an opposed surface opposite the first surface; applying
one or more graphic elements to the first surface to create a
decorated substrate; placing the decorated partially-cured
substrate into a mold for a sole element; and curing the decorated
substrate, wherein at least a portion of each of the first surface
and the opposed surface contact the mold during the step of
curing.
2. The method of claim 1, wherein the step of applying a graphic
element includes applying ink.
3. The method of claim 1, wherein the graphic element includes a
reflective component.
4. The method of claim 1, further including: applying one or more
graphic elements to the opposed surface of the substrate.
5. The method of claim 1, wherein the substrate has a thickness
greater than 0.1 cm.
6. The method of claim 1, wherein the substrate has a thickness
greater than approximately 0.2 cm.
7. The method of claim 1, wherein the substrate has a thickness
greater than approximately 0.3 cm.
8. The method of claim 1, wherein the substrate is a composite
rubber mixture.
9. The method of claim 1, wherein the substrate includes at least
one filler.
10. The method of claim 9, wherein the at least one filler includes
at least one of a carbon fiber, a graphite fiber, a glass fiber and
an aramid fiber.
11. The method of claim 1, further comprising: co-curing at least
one partially-cured ground-contacting element to the first surface
of the substrate during the step of curing.
12. The method of claim 1, wherein the substrate is a pre-form
having at least one relief feature, the relief feature configured
to accommodate a change in geometry of the pre-form from a
substantially flat pre-form to a sole element having
three-dimensional characteristics.
13. The method of claim 12, wherein the relief feature is a
notch.
14. The method of claim 1, wherein the decorated substrate
substantially fills the mold cavity.
15. The method of claim 1, wherein the sole element is an
outsole.
16. A method of forming a sole element for an article of footwear,
comprising: obtaining a partially-cured substrate; applying one or
more graphic elements to a first surface of the substrate to create
a decorated substrate; placing the decorated substrate into a mold
for a sole element; and curing the decorated substrate within the
mold, wherein the decorated substrate substantially fills the
mold.
17. The method of claim 16, wherein the step of applying a graphic
element includes applying ink.
18. The method of claim 17, wherein the ink has a solids content of
from approximately 75% to approximately 95% by volume.
19. The method of claim 16, wherein the graphic element includes a
reflective component.
20. The method of claim 16, further including: applying one or more
graphic elements to a second surface of the substrate.
21. The method of claim 16, wherein the substrate has a thickness
greater than 0.1 cm.
22. The method of claim 16, wherein the substrate has a thickness
greater than approximately 0.2 cm.
23. The method of claim 16, wherein the substrate has a thickness
greater than approximately 0.3 cm.
24. The method of claim 16, wherein the substrate is a composite
rubber mixture.
25. The method of claim 16, wherein the substrate includes at least
one filler.
26. The method of claim 25, wherein the at least one filler
includes at least one of a carbon fiber, a graphite fiber, a glass
fiber and an aramid fiber.
27. The method of claim 16, wherein the substrate is a pre-form
having at least one relief feature, the relief feature configured
to accommodate a change in geometry of the pre-form from a
substantially flat pre-form to a sole element having
three-dimensional characteristics.
28. The method of claim 16, wherein the decorated substrate has an
opposed surface opposite the first surface and wherein the opposed
surface contacts the mold during the step of curing.
29. The method of claim 16, wherein the substrate has an opposed
surface opposite the first surface and wherein at least a portion
of each of the first surface and the opposed surface contact the
mold during the step of curing.
30. The method of claim 16, wherein the sole element is an
outsole.
31. A decorated pre-form for a molded sole element for an article
of footwear, comprising: a partially-cured, substantially flat
material shaped to at least roughly approximate a final shape of
the sole element; and one or more graphic elements on a first
surface of the material, wherein the pre-form has a thickness
greater than 0.1 cm.
32. The pre-form of claim 31, wherein the pre-form includes at
least one relief feature to accommodate a change in geometry of the
material from a substantially flat configuration to a
three-dimensional configuration.
33. The pre-form of claim 32, wherein the relief feature has first
and second edges adapted to substantially abut one another in the
three-dimensional configuration, wherein the graphic elements
include a first graphic element extending toward the first edge of
the relief feature and a second graphic element extending toward
the second edge of the relief feature, and wherein the first and
second graphic elements form a combined graphic element having a
coherent, unified appearance in the three-dimensional
configuration.
34. The pre-form of claim 31, wherein the material has a thickness
greater than approximately 0.15 cm.
35. The pre-form of claim 31, wherein the material has a thickness
greater than approximately 0.25 cm.
36. The pre-form of claim 31, wherein the material has a thickness
greater than approximately 0.35 cm.
37. The pre-form of claim 31, wherein the one or more graphic
elements include at least one of a silk-screened ink, a reflective
component, and a texture component.
38. The pre-form of claim 31, further including one or more graphic
elements on a second surface of the material, wherein the second
surface is opposite to the first surface.
39. The pre-form of claim 31, wherein the material includes a
colorant selected to coordinate with one or more colors of the
graphic elements.
40. An article of footwear comprising: a sole element formed
according to the method of claim 1; and an upper configured to
retain the sole element to a user's foot.
41. A method of forming a sole element for an article of footwear,
comprising: obtaining a partially-cured, substrate having a
thickness greater than approximately 0.15 cm; applying one or more
graphic elements to a surface of the substrate to create a
decorated substrate; placing the decorated substrate into a mold
for a sole element; and curing the decorated substrate within the
mold.
42. The method of claim 41, wherein the substrate has a thickness
greater than approximately 0.25 cm.
43. The method of claim 41, wherein the substrate has a thickness
greater than approximately 0.35 cm.
44. The method of claim 41, wherein the substrate includes a
filler.
45. The method of claim 41, further comprising: obtaining a second,
partially-cured, substrate; placing said second substrate into the
mold for the sole element; and co-curing the second substrate with
the decorated substrate.
Description
FIELD OF THE INVENTION
[0001] The present invention relates to a sole for an article of
footwear. More particularly, various examples of the invention
relate to applying graphic elements to a sole element for an
article of footwear.
BACKGROUND OF THE INVENTION
[0002] Applying brand information, colors, decorations, etc. to the
soles of shoes is desirable. A variety of techniques for creating
such decorated soles have been developed.
[0003] It is known, for example, to apply a color toning additive
to a vulcanized rubber plate and to subsequently apply heat and
pressure via an embossing roller to the coated rubber plate,
thereby forming a marked plate which can be die-cut, sewn, glued,
etc. to form a sole for a shoe.
[0004] It is also known to incorporate a thin layer or skin having
a decorative pattern into a base layer or substrate. In some
examples, a layer of decorative fabric is incorporated into an
injection-molded or compression-molded sole. In another example, a
polymeric membrane having a decorative pattern printed thereon is
placed within a mold cavity and subsequently co-molded to a poured
substrate.
[0005] U.S. Pat. No. 7,188,648 issued to Mellet et al., which is
incorporated herein in its entirety by reference, discloses a
partially cured skin, with a decorative printed pattern facing the
ultimate outer surface. This skin, which has a thickness of from
0.5 mm to 1 mm, is co-molded to a partially-cured substrate to form
a decorated laminated tire tread. Difficulties may occur when
trying to align two substrates within a single mold. Problems may
also arise with the quality of the bond between the two substrates,
particularly with respect to air that may be trapped between the
layers during the bonding process. Further, the thinness of the
skin layer may cause handling problems and require special care
during the co-molding process to prevent undesirable perforation or
tearing of the skin.
[0006] Thus, all of these known techniques have drawbacks. Some
involve multi-step processes, thereby increasing production costs
and time. Others require special handling techniques to protect
and/or properly align the decorative pattern during production.
Even others require multi-layer construction, thereby increasing
the complexity of the process and the chances of introducing flaws
into the finished product.
[0007] Accordingly, it would be desirable to provide decorated
soles for footwear that are easy to produce with a minimum of
handling and with a robust and efficient process.
BRIEF SUMMARY OF THE INVENTION
[0008] Various aspects of the invention relate to a decorated sole
element for footwear. Some aspects of the invention relate to
footwear having such a decorated sole element.
[0009] According to one aspect of the invention, a method of
forming a sole element for an article of footwear includes
obtaining a partially-cured substrate having a first surface and an
opposed surface opposite the first surface and applying one or more
graphic elements to the first surface to create a decorated
substrate. The method further includes placing the decorated
partially-cured substrate into a mold for a sole element and curing
the decorated substrate (e.g., while applying heat and/or
pressure). During curing, at least a portion of each of the first
surface and the opposed surface contacts the mold.
[0010] According to another aspect of the invention, a method of
forming a sole element for an article of footwear includes
obtaining a partially-cured substrate and applying one or more
graphic elements to one or more surfaces of the substrate to create
a decorated substrate. The method further includes placing the
decorated substrate into a mold for a sole element and curing the
decorated substrate within the mold (e.g., while applying heat
and/or pressure). The decorated substrate substantially fills the
mold.
[0011] The graphic elements could include an ink component, a
reflective component, an anti-abrasive component and a textured
component.
[0012] The substrate may have a thickness greater than 0.1 cm, and
optionally may have a thickness greater than approximately 0.15 cm,
greater than approximately 0.2 cm, greater than approximately 0.3
cm or greater than approximately 0.4 cm. The thickness may depend,
at least in part, on the required thickness of the sole element.
The thickness may also depend, at least in part, on the desire to
minimize distortion of the graphic element.
[0013] The substrate may be a composite rubber mixture. Further,
the substrate may contain a filler, for example, carbon, graphite,
glass and/or aramid fibers.
[0014] According to another aspect of the invention, a
partially-cured ground-contacting element may be co-cured to the
first surface of the substrate during the step of curing.
[0015] According to even another aspect of the invention, the
substrate may be a pre-form having at least one relief feature. The
relief feature is configured to accommodate a change in geometry of
the pre-form from a substantially flat pre-form to a sole element
having three-dimensional characteristics. An example of a relief
feature is a notch.
[0016] The sole element may be an outsole, a midsole or any other
portion of a sole structure.
[0017] According to another aspect of the invention, an article of
footwear includes the sole element formed by one of the disclosed
methods and an upper configured to retain the sole element to a
user's foot.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] The foregoing Summary, as well as the following Detailed
Description, will be better understood when read in conjunction
with the accompanying drawings.
[0019] FIG. 1 is a perspective view of an article of footwear
having a decorated sole in accordance with certain aspects of the
invention;
[0020] FIG. 2 is a cross-sectional view through II-II (rotated
180.degree. around a horizontal axis) in accordance with the aspect
of the invention of FIG. 1;
[0021] FIG. 3 is a perspective view of a substrate in accordance
with certain aspects of the invention;
[0022] FIG. 4 is a perspective view of a decorated substrate in
accordance with certain aspects of the invention;
[0023] FIG. 5 is a perspective view of a decorated substrate and a
mold portion for an outsole in accordance with certain aspects of
the invention;
[0024] FIG. 6 is a perspective view of a decorated sole element in
accordance with certain aspects of the invention;
[0025] FIG. 7 is a perspective view of a decorated substrate in
accordance with certain aspects of the invention;
[0026] FIG. 8 is a perspective view of a decorated substrate in
accordance with certain aspects of the invention;
[0027] FIG. 9 is a perspective view of a decorated substrate and a
mold portion for an outsole in accordance with certain aspects of
the invention;
[0028] FIG. 10 is a perspective view of an article of footwear
having a decorated sole in accordance with certain aspects of the
invention;
[0029] FIG. 11 is a perspective view of a decorated substrate in
accordance with certain aspects of the invention;
[0030] FIG. 12 is a perspective view of a decorated substrate and a
mold portion for an outsole in accordance with certain aspects of
the invention;
[0031] FIG. 13 is a perspective view of an article of footwear
having a decorated sole in accordance with certain aspects of the
invention;
[0032] FIG. 14 is a perspective view of a decorated pre-form in
accordance with certain aspects of the invention;
[0033] FIG. 15 is a perspective view of a decorated sole formed
from the pre-form of FIG. 14; and
[0034] FIG. 16 is a perspective view of mold halves in accordance
with other aspects of the invention.
DETAILED DESCRIPTION OF THE INVENTION
[0035] The following discussion and accompanying figures disclose a
decorated sole and an article of footwear having a decorated sole
in accordance with various aspects of the present invention.
Although concepts related to the sole are disclosed with reference
to an article of athletic footwear, the sole is not limited to use
with footwear designed for athletic activities. Thus, the sole
according to various embodiments of the invention may be
incorporated into footwear that is generally considered to be
non-athletic, including a variety of dress shoes, casual shoes,
sandals, and boots.
[0036] An article of footwear 100 is depicted in FIG. 1 as
including a sole structure 20 and an upper 30. Upper 30 may be any
structure designed to hold a sole structure to a foot. As shown in
FIG. 1, upper 30 is secured to sole structure 20 and defines a
space for receiving a foot.
[0037] Sole structure 20 may include more than one sole element 22.
Thus, as illustrated in FIG. 2, sole structure 20 may include both
an outsole 24 and a midsole 26. Midsole 26 may extend all or part
of the way along the length or width of the article of footwear.
Further, midsole 26 may be formed as a single piece or as multiple
pieces. Outsole 24 is typically secured to a lower surface of
midsole 26 with adhesives, as is conventionally known in the art. A
bottom surface 23 of outsole 24 may contact the ground during
ambulatory activities.
[0038] These sole elements may be formed from any suitable
material. Thus, as known in the art, sole element may 22 be formed
of polymer foam material, such as polyurethane or
ethylvinylacetate. This may be particularly suitable for midsole
26. Sole element 22 may be formed of a wear-resistant material,
such as natural or synthetic rubber or a combination thereof. This
may be particularly suitable for outsole 24. One particular
composite rubber mixture may include approximately 75% natural
rubber and 25% synthetic rubber. The synthetic rubber could include
a styrene-butadiene rubber. Other suitable polymeric materials for
outsole 24 include silicone, thermoplastic polyurethane,
polypropylene, polyethylene, ethylvinylacetate, and styrene
ethylbutylene styrene. The material of sole elements 22 may also
include fillers or other components to tailor their wear,
durability, abrasion-resistance, compressibility, stiffness and/or
strength properties. Thus, for example, outsole 24 may include
reinforcing fibers, such as carbon fibers, glass fibers, graphite
fibers, aramid fibers, basalt fibers, etc.
[0039] Various other secondary elements 21, i.e., comfort elements,
motion-control elements, stability elements, ground-contacting
elements, etc., may be incorporated into sole structure 20. For
example, a sockliner 27 may be located on an upper surface of
midsole 26 to provide a comfortable surface for contacting the
foot. As a second example, a comfort element could be a
fluid-filled bladder (not shown) and such bladder may be
incorporated into midsole 26 or located between midsole 26 and
outsole 24. By way of another example, stability elements could
include anti-roll stiffeners, orthotics, pronation control
elements, and the like incorporated or otherwise attached to sole
structure 20. As an example of ground-contacting elements, cleats
or treads may be incorporated or otherwise attached to outsole
24.
[0040] In accordance with an aspect of the invention and referring
to FIGS. 3, 4, 5 and 6, a method for manufacturing a sole element
includes the steps of obtaining a partially cured substrate 40
(S1), transferring a graphic element 50 to the substrate 40 (S2) to
obtain a decorated substrate 44, placing the decorated substrate 44
in a mold 60 (S3), and curing the decorated substrate 44 to form
the sole element 22 (S4). Heat and/or pressure may be applied to
the decorated substrate 44 to form the substrate into the desired,
three dimensional sole element 22 form.
[0041] As shown in FIG. 4, graphic elements 50 may be applied to
the entire surface of substrate 40. Alternatively, as shown in FIG.
7, graphic elements 50 may be applied to only a portion of
substrate 40. In the embodiment shown in FIG. 7, graphic elements
50 are applied only to that portion of substrate 40 that will
eventually form the sole element. The graphic elements 50 may be
applied to an even smaller portion of the substrate 40 surface, if
desired.
[0042] In one embodiment, referring back to FIGS. 1, 2 and 6,
outsole 24 may be a cup sole 28 formed as a single piece. Cup sole
28 includes a bottom surface 23 framed by upwardly extending side
walls 25. As best shown in FIGS. 1 and 6, the external surface of
outsole 24, including the bottom surface 23 and the external
surfaces of side walls 25, has been decorated with a printed ink
pattern.
[0043] As best shown in FIG. 3, substrate 40 may be formed as a
substantially flat substrate. Substrate 40 may be formed of a
polymer foam material. As one example, mentioned above, substrate
40 may be formed as a hybrid rubber plate having approximately 75%
natural rubber and 25% synthetic rubber (75/25 rubber composite
hybrid).
[0044] Substrate 40 is partially cured. As an example, the 75/25
rubber composite hybrid substrate may be cured for approximately
300 to 350 seconds at a temperature of approximately 350.degree. C.
under a pressure of approximately 2000 pounds/square inch, thereby
achieving a substantially half-cured rubber product. Other partial
cure times, temperatures and pressures for a variety of different
materials would be apparent to and determined by persons of
ordinary skill in the art, given the benefit of this
disclosure.
[0045] Substrate 40 may have a thickness, t, which is suitable for
substantially filling the mold and/or for forming a complete sole
element 22. The optimum thickness of substrate 40 may be selected
based on the material properties of the substrate and the desired
finished properties of the sole element 22. For example,
light-weight running shoes require a lighter weigh sole that
standard running shoes, while standard hiking boots require a
heavier duty sole than running shoes. In one embodiment, the
thickness of substrate 40 may be greater than 0.1 cm for ease of
handling the substrate. Optionally, the thickness of substrate 40
may be greater than approximately 0.15 or 0.2 cm in order to
provide, for example, sufficient material to easily handle the
finished sole element 22. As another option, the thickness of
substrate 40 may be greater than approximately 0.3 cm in order to
provide sufficient material to create, for example, a more durable
outsole 24 or to provide sufficient material for forming treads or
other ground contacting elements. As even another option, the
thickness of substrate 40 may be greater than approximately 0.4 cm
or even up to approximately 0.5 cm in order to provide, for
example, sufficient material to form even more rugged outsoles or
to form deeper ground contacting elements.
[0046] Further, substrate 40 may be provided with a thickness for
optimizing the quality of the finished graphic elements. In
general, increasing the thickness of substrate 40 results in less
deformation of the substrate during application of the graphics and
therefore less deformation or distortion of the graphic elements.
Thus, a thickness of substrate 40 approximately 0.1 to
approximately 0.15 may provide sufficient stability to allow for a
minimally distorted graphic element. Increasing the thickness of
substrate 40 above approximately 0.10 or above approximately 0.2 cm
would result in even less distortion of the graphic elements.
Providing a substrate above approximately 0.3 cm provides even
better image stability, while providing a substrate having a
thickness above approximately 0.4 cm results in significantly less
deformation than a substrate having a thickness less than 0.1
cm.
[0047] As noted above, and as best shown in FIGS. 2, 7, 8, 11 and
14, in one aspect of the invention, graphic elements 50 are applied
to at least some portions of a surface of substrate 40. Graphic
elements 50 may be applied as ink via printing, such as a silk
screening process, a digital printing process, an ink jet printing
process or other types of printing processes that are
conventionally known and/or used in the art. In the case of a silk
screening process, one or more silk screens may be created--with
one screen created per each color to be applied. The most suitable
characteristics of the screen mesh for the silk screening process
are determined by the ink manufacturer's recommendation or, if
necessary, by experimentation. Depending upon the ink and its
dilution, multiple screening passes may be preferred to achieve the
desired opacity of the graphics. Further, when applying light
colors over dark substrates, a base intensifier ink layer, such as
a base white intensifier ink, may be desired.
[0048] One suitable ink product that may be used in accordance with
at least some examples of this invention is produced by Union
Process, Inc. of Akron, Ohio. Union Process's silkscreen ink (800
series) is a highly viscous ink for use in a silk screening method
for decorating rubber latex objects. These silk screen inks are
typically concentrated and may be diluted, according to the
manufacturer's instructions, with a mineral spirit solvent in the
range of 30% solvent to 70% ink by volume. In one aspect of the
present invention, the concentrated silk screen ink may be diluted
with mineral spirit solvent in the range from approximately 5% to
approximately 25% by volume, more preferably in the range of from
approximately 10% to approximately 20% by volume, thereby producing
an ink with a relatively high solids content. These high solids
content inks have a relatively high viscosity and may provide
better coverage. This may result in achieving a given opacity of
the graphic element in fewer passes or applications of the ink. In
one particular aspect, the concentrated silk screen ink is diluted
with approximately 10% by volume of mineral spirit solvent. The
solvent can be a fast drying solvent. After application, the ink
may be air dried for 3 to 5 minutes. Optionally, a dryer may be
used to dry the ink after application. A suitable mesh for applying
these 800 series inks ranges from 200-325 mesh.
[0049] Alternatively, graphic elements 50 may be applied to
substrate 40 as decals transferred from a carrier film. Such decals
may include ink decals, rubber decals or other polymeric or
non-polymeric materials. Other methods of applying graphic elements
50 to the surface of the substrate 40 would be apparent to persons
of skill in the art, given the benefit of this disclosure.
[0050] Graphic elements 50 may be used to apply logos, brand names,
manufacturing or source indicia, style identification, size, etc.
Graphic elements may be used to apply colored patterns, including
mono-colored or multi-colored patterns. Graphic elements may
include reflective, phosphorescent, anti-abrasion, textured, etc.
components.
[0051] In one embodiment, graphic elements 50 may be applied to
both sides of substrate 40, such that decorated substrate 44
includes graphic elements 50 on opposing surfaces. This may be
particularly suitable, for example, when the article of footwear is
a flip-flop or sandal or other article of footwear wherein both the
upper and lower surfaces of the sole element 20 are visible.
[0052] In another embodiment, the material of substrate 40 may be
provided with a colorant. The material of the substrate may be
provided with a colorant that completely permeates the substrate.
In one aspect, the color of the substrate material may be
coordinated with the applied graphic elements 50. Thus, by way of
non-limiting example, substrate 40 may be formed of a rubber-like
material having an integral color that complements the colors of
the graphic elements. Optionally, the color of the material of the
substrate may be of the same family as the base color (or as an
accent color) of the graphic elements. By coordinating the color of
the material of the substrate with the colors of the graphic
elements, less ink may need to be applied to achieve the final
desired graphic element colors. For example, the material of the
substrate may be a dark blue and the color of the graphic elements
may be light and/or medium blues. In certain aspects, the color of
the material of the substrate may be coordinated with the graphics
elements such that openings in the graphic elements, which allow
the color of the substrate to be exposed, may be part of the
overall design of the ultimate sole element. In other aspects, the
color of the material of the substrate may be chosen to provide
very little contrast between the substrate and the graphic
elements. This may be desired if the graphic elements were to wear
away, thereby exposing the underlying substrate.
[0053] According to another aspect of the invention, and referring
back to FIG. 5, after graphic elements 50 are applied to substrate
40, the decorated substrate 44 is transferred to a mold 60 having a
mold cavity 62. Mold 60 may be a two-piece compression mold, for
example, with mold halves 60a, 60b as shown in FIG. 16. Depending
upon the material of the substrate, heat and/or pressure may be
applied to the substrate 40 within the mold 60 to further shape the
substrate 40 and/or to further cure the partially cured substrate
40. In one embodiment, the material of the substrate is a 75/25
rubber composite hybrid having a thickness of at least 0.1 cm.
Final curing conditions of this substrate 40 within the mold 60
include applying a temperature of approximately 350.degree. C.
under a pressure of approximately 2000 pounds/square inch for
approximately 300 to 350 seconds.
[0054] Additionally, a second, partially-cured substrate may be
placed within mold 60 with the first, decorated substrate 40. The
first and second substrates may be co-cured together. The first and
second substrates may be formed of the same or different materials.
They may have the same or different dimensions. The second
substrate may or may not be decorated.
[0055] In another embodiment, as shown in FIGS. 8, 9 and 10,
outsole 24 includes ground-contacting elements 29 formed from
decorated substrate 44. In this exemplary embodiment,
ground-contacting elements 29 are shown as treads. As best shown in
FIG. 9, mold 60 may have a plurality of sub-cavities 64
incorporated into its mold cavity 62. Thus, when decorated
substrate 44 is shaped and cured within mold 60, decorated
substrate 44 conforms to mold cavity 62 and to mold sub-cavities
64. In this embodiment, decorated substrate 44 substantially fills
the mold cavity 62 and both the decorated and undecorated surfaces
of decorated substrate 44 contact surfaces of mold cavity 62 during
the steps of shaping and curing.
[0056] As best shown in FIGS. 8 and 10, graphic element 50 may
include graphic element portions 50a, 50b that visually
differentiate or highlight the ground-contacting elements 29. For
example, graphic element portions 50a may be applied to those areas
of outsole 24 that form the ground-contacting elements 29. Graphic
element portions 50b may be applied to areas of outsole 24 not
contacting the ground. In one embodiment, at least graphic element
portions 50b may include a reflective component. Because portions
50b do not contact the ground, the graphic element in that area
will not be worn away due to ground contact and the reflective
component will be retained throughout the life of the article of
footwear. Alternatively, because portions 50a do contact the ground
and therefore may be worn away during use, the ground-contacting
areas of the outsole 24 may be left undecorated, if desired. In
such case, graphic element 50 may include only portion 50b.
[0057] Alternatively, as best shown in FIGS. 11, 12 and 13, outsole
24 may include ground-contacting elements 29 co-molded to decorated
substrate 44. In this exemplary embodiment, ground-contacting
elements 29 are also shown as treads. As best shown in FIG. 12,
mold 60 may again have a plurality of sub-cavities 64 incorporated
into its mold cavity 62. In this embodiment, sub-cavities 64 are
filled (or partially filled) with partially-cured treads. Thus,
when decorated substrate 44 is placed and cured within mold 60, it
conforms to mold cavity 62 and is co-molded to the partially-cured
treads located in sub-cavities 64. In this embodiment, decorated
substrate 44 substantially fills the mold cavity even though a
portion of the mold cavity is filled with partially-cured ground
contacting elements 29. Furthermore, both the decorated and
undecorated surfaces of decorated substrate 44 contact the surfaces
of mold cavity 62 during the steps of shaping and curing, even
though only a portion of the decorated surface of substrate 44
contacts a surface of mold cavity 62.
[0058] As best shown in FIG. 11, graphic element 50, as applied to
substrate 40, may cover only those portions of outsole 24 that will
be visible after being co-molded to the ground-contacting elements
29. Although this would conserve ink (if the graphic element is,
for example, formed via a silk screening process), the decorated
substrate 44 would need to be properly and carefully aligned within
mold 60. Alternatively, graphic element 50 could extend over the
entire area of outsole 24 (see, for example, FIG. 7) or even over
the entire area of substrate 40 (see, for example, FIG. 4). Again,
graphic element 50 may include a reflective component. For example,
the circular design elements of graphic element 50 may be
reflective (e.g., printed using an ink that contains a light
reflecting component). As another embodiment, ground-contacting
elements 29 may be cleat elements.
[0059] Referring to FIG. 14, substrate 40 may be fashioned as a
pre-form 42. A pre-form is shaped to at least roughly approximate
the final shape of the sole element 22. In one embodiment, pre-form
42 is cut, punched, or otherwise shaped from substrate 40 after the
step of applying graphic elements 50 (as disclosed below). Applying
the graphic elements before creating pre-form 42 may be
particularly suitable when the ultimate placement or alignment of
the graphic elements on sole element 22 is not of great concern. In
another embodiment, pre-form 42 may be cut, punched or otherwise
shaped from substrate 40 prior to the step of applying graphic
elements 50. This may be particularly suitable when the ultimate
placement of the graphic elements is meant to be in alignment with
certain features of sole element 22. In this case, a registration
template may be used to align graphic elements 50 on pre-form 42
and/or to provide a level surface for applying the graphic elements
thereto.
[0060] In one embodiment, substrate 40 or pre-form 42 may include
one or more relief features 45. Relief feature 45 is meant to allow
the substantially flat substrate to more easily conform to the
three-dimensional aspects of the mold. Thus, for example, as shown
in FIG. 14, pre-form 42 may include notches or darts along the
edges of pre-form 42 to allow the pre-form to assume a
three-dimensional shape (e.g., of a cup sole) without wrinkling,
overlapping, or folding. Graphic elements 50 may be applied to a
pre-form 42 having these relief features such that after molding,
the graphic elements form a continuous, non-disrupted design across
the three-dimensional relief feature in its three-dimensional
configuration. Thus, according to one aspect, a first graphic
element 52a may be applied to a portion of the pre-form surface
that lies adjacent one edge 45a of the relief feature and a second
graphic element 52b may be applied to a portion of the pre-form
surface that lies adjacent another edge 45b of the relief feature.
When pre-form 42 is molded into its three-dimensional
configuration, as best shown in FIG. 15, edges 45a, 45b of relief
feature 45 abut one another and the first and second graphic
elements 52a, 52b form complementary portions of a combined graphic
element 54, such that the combined graphic element has a coherent,
unified and pleasing visual appearance.
[0061] Referring to FIG. 16, in one embodiment, mold 60 may have an
undercut feature 66 on mold half 60a. Undercut feature 66 provides
registration for a decorated pre-form. This undercut feature 66 may
also provide mold closure clearance and assist in reducing any
potential distortion of the graphic elements on the pre-form when
the mold halves 60a, 60b are closed.
[0062] While the invention has been described with respect to
specific examples including presently preferred modes of carrying
out the invention, those skilled in the art, given the benefit of
this disclosure, will appreciate that there are numerous variations
and permutations of the above described systems and techniques that
fall within the spirit and scope of the invention as set forth
above. All examples, whether preceded by "for example," "such as,"
"including, or other itemizing terms or followed by "etc.," are
meant to be non-limiting examples, unless otherwise stated or
obvious from the context of the specification.
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