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.

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.