Footwear outsole and method of manufacture

Abstract

An outsole construction having an integral display layer. The outsole includes a main body and a plurality of lugs extending from the main body to define a plurality of ground engaging elements. The display layer is disposed at the surface of the main body such that it is visible in the main body of the outsole and is spaced away from the surface of the lugs such that it is not visible on the surface of the lugs. The display layer may include a printed pattern, such as a camouflage pattern. The present invention also provides a method for manufacturing an outsole including the general steps of (a) providing a mold defining a main body and a plurality of lugs extending from the main body, (b) placing a permeable display layer in the mold and (c) injecting sole material into the mold. In this method, the permeability of the display layer and/or the viscosity of the sole material may be selected so that the display layer lies along the surface of the main body of the sole but not the surface of the lugs.

1 . An outsole comprising: 
 a main body having an outer surface;    a plurality of lugs integral with and extending from said main body, said plurality of lugs extending from said outer surface to define a plurality of ground engaging surfaces;    a display layer integral with the outsole, said display layer extending along said outer surface of said main body whereby said display layer is visible on said outer surface, said display layer being embedded within the outsole above said ground engaging surfaces of said plurality of lugs whereby said display layer is hidden from view above said ground engaging surfaces.    
     
     
         2 . The outsole of  claim 1  wherein said display layer is coextensive with the outsole.  
     
     
         3 . The outsole of  claim 1  wherein said main body and said plurality of lugs are manufactured from an opaque sole material.  
     
     
         4 . The outsole of  claim 1  wherein said display layer includes a pattern, said pattern being visible on said outer surface of said main body and not being visible on said ground engaging surface of said plurality of lugs.  
     
     
         5 . The outsole of  claim 1  wherein said display layer is permeable.  
     
     
         6 . The outsole of  claim 1  wherein said display layer is a fabric.  
     
     
         7 . The outsole of  claim 1  wherein said display layer is a tricot fabric.  
     
     
         8 . The outsole of  claim 4  wherein said pattern is further defined as a camouflage pattern.  
     
     
         9 . An article of footwear comprising: 
 an upper; and    a sole affixed to said upper;    wherein said sole includes a sole component having an integral display layer, said sole component including a main body and a plurality of lugs extending from said main body, said lugs defining a plurality of ground engaging surfaces, said display layer being visible along a surface of said main body and not being visible along said ground engaging surfaces of said plurality of lugs.    
     
     
         10 . The article of  claim 9  wherein said main body includes an outer surface, said display layer being visible along said outer surface.  
     
     
         11 . The article of  claim 10  wherein said lugs extend from said outer surface, whereby said display layer is visible on said main body around said plurality of lugs.  
     
     
         12 . The article of  claim 11  wherein said display layer includes permeable regions at least adjacent said plurality of lugs.  
     
     
         13 . The article of  claim 11  wherein said display layer is manufactured from a permeable material.  
     
     
         14 . The article of  claim 13  wherein said display layer is a fabric.  
     
     
         15 . The article of  claim 13  wherein said display layer is a tricot fabric having a camouflage pattern.  
     
     
         16 . The article of  claim 11  wherein said display layer is visible along and coextensive with said outer surface of said main body.  
     
     
         17 - 24 . (canceled)  
     
     
         25 . An outsole comprising: 
 a main body having an outer surface;    a plurality of lugs molded integral with and extending from said main body, said plurality of lugs extending from said outer surface to define a plurality of ground engaging surfaces;    a fabric display layer integral with the outsole and defining a plurality of interstices, said display layer extending along said outer surface of said main body whereby said display layer is visible on said outer surface, said display layer being embedded within the outsole above said ground engaging surfaces of said plurality of lugs with portions of said lugs extending through said interstices, whereby said display layer is hidden from view above said ground engaging surfaces.