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US20100031535A1 - Printed sole for a shoe and method of making - Google Patents

Printed sole for a shoe and method of making Download PDF

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Publication number
US20100031535A1
US20100031535A1 US12/186,017 US18601708A US2010031535A1 US 20100031535 A1 US20100031535 A1 US 20100031535A1 US 18601708 A US18601708 A US 18601708A US 2010031535 A1 US2010031535 A1 US 2010031535A1
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US
United States
Prior art keywords
substrate
decorated
mold
approximately
sole element
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Abandoned
Application number
US12/186,017
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English (en)
Inventor
Gregory Ross Leedy
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Nike Inc
Original Assignee
Individual
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Individual filed Critical Individual
Priority to US12/186,017 priority Critical patent/US20100031535A1/en
Assigned to NIKE, INC. reassignment NIKE, INC. ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: LEEDY, GREGORY ROSS
Priority to PCT/US2009/052659 priority patent/WO2010017173A1/fr
Priority to CN2009801309594A priority patent/CN102177005A/zh
Publication of US20100031535A1 publication Critical patent/US20100031535A1/en
Abandoned legal-status Critical Current

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
    • B29C43/02—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor of articles of definite length, i.e. discrete articles
    • B29C43/14—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor of articles of definite length, i.e. discrete articles in several steps
    • B29C43/145—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor of articles of definite length, i.e. discrete articles in several steps for making multicoloured articles
    • A—HUMAN NECESSITIES
    • A43—FOOTWEAR
    • A43B—CHARACTERISTIC FEATURES OF FOOTWEAR; PARTS OF FOOTWEAR
    • A43B1/00—Footwear characterised by the material
    • A43B1/0027—Footwear characterised by the material made at least partially from a material having special colours
    • A—HUMAN NECESSITIES
    • A43—FOOTWEAR
    • A43B—CHARACTERISTIC FEATURES OF FOOTWEAR; PARTS OF FOOTWEAR
    • A43B13/00—Soles; Sole-and-heel integral units
    • A43B13/14—Soles; Sole-and-heel integral units characterised by the constructive form
    • A43B13/22—Soles made slip-preventing or wear-resisting, e.g. by impregnation or spreading a wear-resisting layer
    • A43B13/223—Profiled soles
    • A—HUMAN NECESSITIES
    • A43—FOOTWEAR
    • A43B—CHARACTERISTIC FEATURES OF FOOTWEAR; PARTS OF FOOTWEAR
    • A43B23/00—Uppers; Boot legs; Stiffeners; Other single parts of footwear
    • A43B23/24—Ornamental buckles; Other ornaments for shoes without fastening function
    • A—HUMAN NECESSITIES
    • A43—FOOTWEAR
    • A43B—CHARACTERISTIC FEATURES OF FOOTWEAR; PARTS OF FOOTWEAR
    • A43B3/00—Footwear characterised by the shape or the use
    • A43B3/0036—Footwear characterised by the shape or the use characterised by a special shape or design
    • A43B3/0078—Footwear characterised by the shape or the use characterised by a special shape or design provided with logos, letters, signatures or the like decoration
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
    • B29C43/02—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor of articles of definite length, i.e. discrete articles
    • B29C43/021—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor of articles of definite length, i.e. discrete articles characterised by the shape of the surface
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
    • B29C43/02—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor of articles of definite length, i.e. discrete articles
    • B29C43/20—Making multilayered or multicoloured articles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29D—PRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE
    • B29D35/00—Producing footwear
    • B29D35/0054—Producing footwear by compression moulding, vulcanising or the like; Apparatus therefor
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29D—PRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE
    • B29D35/00—Producing footwear
    • B29D35/12—Producing parts thereof, e.g. soles, heels, uppers, by a moulding technique
    • B29D35/14—Multilayered parts
    • B29D35/142—Soles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
    • B29C43/02—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor of articles of definite length, i.e. discrete articles
    • B29C43/021—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor of articles of definite length, i.e. discrete articles characterised by the shape of the surface
    • B29C2043/023—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor of articles of definite length, i.e. discrete articles characterised by the shape of the surface having a plurality of grooves
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2021/00—Use of unspecified rubbers as moulding material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2995/00—Properties of moulding materials, reinforcements, fillers, preformed parts or moulds
    • B29K2995/0018—Properties of moulding materials, reinforcements, fillers, preformed parts or moulds having particular optical properties, e.g. fluorescent or phosphorescent
    • B29K2995/003—Reflective
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2031/00—Other particular articles
    • B29L2031/48—Wearing apparel
    • B29L2031/50—Footwear, e.g. shoes or parts thereof
    • B29L2031/504—Soles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2031/00—Other particular articles
    • B29L2031/722—Decorative or ornamental articles

Definitions

  • 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.
  • a thin layer or skin having a decorative pattern into a base layer or substrate.
  • a layer of decorative fabric is incorporated into an injection-molded or compression-molded sole.
  • a polymeric membrane having a decorative pattern printed thereon is placed within a mold cavity and subsequently co-molded to a poured substrate.
  • 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.
  • 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.
  • 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.
  • 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.
  • the graphic elements could include an ink component, a reflective component, an anti-abrasive component and a textured component.
  • 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.
  • the substrate may be a composite rubber mixture. Further, the substrate may contain a filler, for example, carbon, graphite, glass and/or aramid fibers.
  • a partially-cured ground-contacting element may be co-cured to the first surface of the substrate during the step of curing.
  • 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.
  • the sole element may be an outsole, a midsole or any other portion of a sole structure.
  • 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.
  • FIG. 1 is a perspective view of an article of footwear having a decorated sole in accordance with certain aspects of the invention
  • FIG. 2 is a cross-sectional view through II-II (rotated 180° around a horizontal axis) in accordance with the aspect of the invention of FIG. 1 ;
  • FIG. 3 is a perspective view of a substrate in accordance with certain aspects of the invention.
  • FIG. 4 is a perspective view of a decorated substrate in accordance with certain aspects of the invention.
  • 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.
  • FIG. 6 is a perspective view of a decorated sole element in accordance with certain aspects of the invention.
  • FIG. 7 is a perspective view of a decorated substrate in accordance with certain aspects of the invention.
  • FIG. 8 is a perspective view of a decorated substrate in accordance with certain aspects of the invention.
  • 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.
  • FIG. 10 is a perspective view of an article of footwear having a decorated sole in accordance with certain aspects of the invention.
  • FIG. 11 is a perspective view of a decorated substrate in accordance with certain aspects of the invention.
  • 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.
  • FIG. 13 is a perspective view of an article of footwear having a decorated sole in accordance with certain aspects of the invention.
  • FIG. 14 is a perspective view of a decorated pre-form in accordance with certain aspects of the invention.
  • FIG. 15 is a perspective view of a decorated sole formed from the pre-form of FIG. 14 ;
  • FIG. 16 is a perspective view of mold halves in accordance with other aspects of the invention.
  • 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.
  • 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.
  • 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.
  • FIG. 1 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.
  • Sole structure 20 may include more than one sole element 22 .
  • 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.
  • sole element 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.
  • outsole 24 examples 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.
  • outsole 24 may include reinforcing fibers, such as carbon fibers, glass fibers, graphite fibers, aramid fibers, basalt fibers, etc.
  • Various other secondary elements 21 may be incorporated into sole structure 20 .
  • a sockliner 27 may be located on an upper surface of midsole 26 to provide a comfortable surface for contacting the foot.
  • 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 .
  • stability elements could include anti-roll stiffeners, orthotics, pronation control elements, and the like incorporated or otherwise attached to sole structure 20 .
  • cleats or treads may be incorporated or otherwise attached to outsole 24 .
  • a method for manufacturing a sole element includes the steps of obtaining a partially cured substrate 40 (S 1 ), transferring a graphic element 50 to the substrate 40 (S 2 ) to obtain a decorated substrate 44 , placing the decorated substrate 44 in a mold 60 (S 3 ), and curing the decorated substrate 44 to form the sole element 22 (S 4 ). 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.
  • graphic elements 50 may be applied to the entire surface of substrate 40 .
  • graphic elements 50 may be applied to only a portion of substrate 40 .
  • 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.
  • 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 .
  • 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.
  • substrate 40 may be formed as a substantially flat substrate.
  • Substrate 40 may be formed of a polymer foam material.
  • substrate 40 may be formed as a hybrid rubber plate having approximately 75% natural rubber and 25% synthetic rubber (75/25 rubber composite hybrid).
  • Substrate 40 is partially cured.
  • the 75/25 rubber composite hybrid substrate may be cured for approximately 300 to 350 seconds at a temperature of approximately 350° 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.
  • 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.
  • the thickness of substrate 40 may be greater than 0.1 cm for ease of handling the substrate.
  • 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 .
  • 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.
  • substrate 40 may be provided with a thickness for optimizing the quality of the finished graphic elements.
  • 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.
  • 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.
  • 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.
  • 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.
  • a base intensifier ink layer such as a base white intensifier ink, may be desired.
  • 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.
  • 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.
  • the concentrated silk screen ink is diluted with approximately 10% by volume of mineral spirit solvent.
  • the solvent can be a fast drying solvent.
  • the ink may be air dried for 3 to 5 minutes.
  • 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.
  • graphic elements 50 may be applied to substrate 40 as decals transferred from a carrier film.
  • 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.
  • 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.
  • 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.
  • 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.
  • the color of the substrate material may be coordinated with the applied graphic elements 50 .
  • substrate 40 may be formed of a rubber-like material having an integral color that complements the colors of the graphic elements.
  • 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.
  • the material of the substrate may be a dark blue and the color of the graphic elements may be light and/or medium blues.
  • 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.
  • 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.
  • 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 60 a, 60 b as shown in FIG. 16 .
  • 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 .
  • 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° C. under a pressure of approximately 2000 pounds/square inch for approximately 300 to 350 seconds.
  • 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.
  • outsole 24 includes ground-contacting elements 29 formed from decorated substrate 44 .
  • ground-contacting elements 29 are shown as treads.
  • mold 60 may have a plurality of sub-cavities 64 incorporated into its mold cavity 62 .
  • decorated substrate 44 conforms to mold cavity 62 and to mold sub-cavities 64 .
  • 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.
  • graphic element 50 may include graphic element portions 50 a, 50 b that visually differentiate or highlight the ground-contacting elements 29 .
  • graphic element portions 50 a may be applied to those areas of outsole 24 that form the ground-contacting elements 29 .
  • Graphic element portions 50 b may be applied to areas of outsole 24 not contacting the ground.
  • at least graphic element portions 50 b may include a reflective component. Because portions 50 b 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 50 a 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 50 b.
  • outsole 24 may include ground-contacting elements 29 co-molded to decorated substrate 44 .
  • ground-contacting elements 29 are also shown as treads.
  • mold 60 may again have a plurality of sub-cavities 64 incorporated into its mold cavity 62 .
  • sub-cavities 64 are filled (or partially filled) with partially-cured treads.
  • 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 .
  • graphic element 50 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 .
  • 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 ).
  • graphic element 50 may include a reflective component.
  • the circular design elements of graphic element 50 may be reflective (e.g., printed using an ink that contains a light reflecting component).
  • ground-contacting elements 29 may be cleat elements.
  • 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 .
  • 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.
  • 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 .
  • 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.
  • 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.
  • 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.
  • a first graphic element 52 a may be applied to a portion of the pre-form surface that lies adjacent one edge 45 a of the relief feature and a second graphic element 52 b may be applied to a portion of the pre-form surface that lies adjacent another edge 45 b of the relief feature.
  • edges 45 a , 45 b of relief feature 45 abut one another and the first and second graphic elements 52 a , 52 b form complementary portions of a combined graphic element 54 , such that the combined graphic element has a coherent, unified and pleasing visual appearance.
  • mold 60 may have an undercut feature 66 on mold half 60 a.
  • 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 60 a, 60 b are closed.

Landscapes

  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Footwear And Its Accessory, Manufacturing Method And Apparatuses (AREA)
US12/186,017 2008-08-05 2008-08-05 Printed sole for a shoe and method of making Abandoned US20100031535A1 (en)

Priority Applications (3)

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US12/186,017 US20100031535A1 (en) 2008-08-05 2008-08-05 Printed sole for a shoe and method of making
PCT/US2009/052659 WO2010017173A1 (fr) 2008-08-05 2009-08-04 Semelle imprimée pour chaussure et procédé pour sa fabrication
CN2009801309594A CN102177005A (zh) 2008-08-05 2009-08-04 用于鞋的印刷式鞋底和制作方法

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
US12/186,017 US20100031535A1 (en) 2008-08-05 2008-08-05 Printed sole for a shoe and method of making

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ITUB20152152A1 (it) * 2015-07-15 2017-01-15 Lelli Kelly S P A Procedimento per la realizzazione di suole trasparenti e/o colorate per calzature.
CN108471838A (zh) * 2015-10-29 2018-08-31 耐克创新有限合伙公司 根据基材轮廓印刷层
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WO2010017173A1 (fr) 2010-02-11

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