WO2010017173A1

WO2010017173A1 - Printed sole for a shoe and method of making

Info

Publication number: WO2010017173A1
Application number: PCT/US2009/052659
Authority: WO
Inventors: Gregory Ross Leedy
Original assignee: Nike Inc; Nike International Ltd
Current assignee: Nike Inc; Nike International Ltd
Priority date: 2008-08-05
Filing date: 2009-08-04
Publication date: 2010-02-11
Anticipated expiration: 2011-02-05
Also published as: US20100031535A1; CN102177005A

Abstract

A method of forming a sole element (22) for an article of footwear includes obtaining a partially-cured substrate (40) having a first surface and an opposed surface opposite the first surface and applying one or more graphic elements (50) to the first surface to create a decorated substrate (44). 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.

Description

PRINTED SOLE FOR A SHOE AND METHOD OF MAKING

RELATED APPLICATIONS

[0001] This application claims the benefit of priority from U.S. Application No. 12/186,017, filed August 5, 2008.

FIELD OF THE INVENTION

[0002] 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

[0003] 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.

[0004] 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.

[0005] 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.

[0006] U.S. Patent 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.

[0007] 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.

[0008] 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

[0009] 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.

[0010] 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.

[001 1] 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.

[0012] The graphic elements could include an ink component, a reflective component, an anti-abrasive component and a textured component.

[0013] 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.

[0014] The substrate may be a composite rubber mixture. Further, the substrate may contain a filler, for example, carbon, graphite, glass and/or aramid fibers.

[0015] 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.

[0016] 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.

[0017] The sole element may be an outsole, a midsole or any other portion of a sole structure.

[0018] 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 [0019] The foregoing Summary, as well as the following Detailed Description, will be better understood when read in conjunction with the accompanying drawings.

[0020] FIG. 1 is a perspective view of an article of footwear having a decorated sole in accordance with certain aspects of the invention;

[0021] 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;

[0022] FIG. 3 is a perspective view of a substrate in accordance with certain aspects of the invention;

[0023] FIG. 4 is a perspective view of a decorated substrate in accordance with certain aspects of the invention;

[0024] 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;

[0025] FIG. 6 is a perspective view of a decorated sole element in accordance with certain aspects of the invention;

[0026] FIG. 7 is a perspective view of a decorated substrate in accordance with certain aspects of the invention;

[0027] FIG. 8 is a perspective view of a decorated substrate in accordance with certain aspects of the invention;

[0028] 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;

[0029] FIG. 10 is a perspective view of an article of footwear having a decorated sole in accordance with certain aspects of the invention; [0030] FIG. 11 is a perspective view of a decorated substrate in accordance with certain aspects of the invention;

[0031] 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;

[0032] FIG. 13 is a perspective view of an article of footwear having a decorated sole in accordance with certain aspects of the invention;

[0033] FIG. 14 is a perspective view of a decorated pre-form in accordance with certain aspects of the invention;

[0034] FIG. 15 is a perspective view of a decorated sole formed from the pre-form of FIG. 14; and

[0035] FIG. 16 is a perspective view of mold halves in accordance with other aspects of the invention.

DETAILED DESCRIPTION OF THE INVENTION

[0036] 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.

[0037] 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. [0038] 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.

[0039] 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.

[0040] 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.

[0041] 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 (Sl), 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.

[0042] 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.

[0043] 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.

[0044] 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).

[0045] 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° 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.

[0046] 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.

[0047] 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.

[0048] 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.

[0049] 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.

[0050] 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.

[0051] 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.

[0052] 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.

[0053] 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.

[0054] 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° C under a pressure of approximately 2000 pounds/square inch for approximately 300 to 350 seconds. [0055] 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.

[0056] 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.

[0057] 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.

[0058] 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.

[0059] As best shown in FIG. 1 1, 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.

[0060] 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.

[0061] 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 preform 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.

[0062] 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.

[0063] 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.

Claims

What is claimed:

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.