Vacuum sublimination process for forming outsoles of articles of footwear

Abstract

A method for forming a graphic on an outsole for an article of footwear can include preparing an outsole plate for the outsole for graphic sublimation, the outsole plate comprising a plurality of cleat members that protrude outwardly from a base surface of the outsole plate, and mounting the outsole plate within a tray. The method can further include positioning a printed film comprising a graphic over the outsole plate and the tray and positioning the tray assembly inside a vacuum-sublimation oven. The method can further include selecting a pressure, temperature, and duration for transferring the graphic to the outsole plate based on a type of graphic on the printed film, a texture and material of the outsole plate, and a height difference of cleat members on the outsole plate, and activating the vacuum-sublimation oven to transfer the graphic to the outsole plate at the selected pressure, temperature, and duration.

1 . A method for forming a graphic on an outsole for an article of footwear, comprising:
 preparing an outsole plate for the outsole for graphic sublimation, the outsole plate comprising a plurality of cleat members that protrude outwardly from a base surface of the outsole plate, and mounting the outsole plate within a tray;   positioning a printed film comprising a graphic over the outsole plate and the tray to form a tray assembly and positioning the tray assembly inside a vacuum-sublimation oven;   selecting a pressure, temperature, and duration for transferring the graphic on the printed film to the outsole plate based on each of a type of graphic on the printed film, a texture of the outsole plate, a height difference of the cleat members on the outsole plate, and a material of the outsole plate; and   activating the vacuum-sublimation oven to transfer the graphic on the printed film to the outsole plate at the selected pressure, temperature, and duration such that the graphic is formed over at least a first portion of the base surface and cleat members protruding from the first portion of the base surface.   
     
     
         2 . The method of  claim 1 , wherein the preparing the outsole plate includes pre-heating the outsole plate. 
     
     
         3 . The method of  claim 2 , further comprising, following pre-heating the outsole plate, cleaning the outsole plate and pre-heating the cleaned outsole plate prior to mounting the outsole plate within the tray. 
     
     
         4 . The method of  claim 1 , further comprising masking the outsole plate by covering a second portion of the base surface and cleat members protruding from the second portion of the base surface with a covering element, prior to mounting the outsole plate within the tray, and further comprising, after transferring the graphic on the printed film to the outsole plate, removing the printed film and the covering element to reveal the graphic formed over the first portion of the base surface and the cleat members protruding therefrom and not on the second portion of the base surface and the cleat members protruding therefrom. 
     
     
         5 . The method of  claim 1 , wherein the selected temperature is in a range of 110 to 140 degree Celsius and the selected duration is in a range of 300 to 500 seconds. 
     
     
         6 . The method of  claim 1 , wherein selecting the pressure, temperature and duration based on the type of graphic on the printed film includes selecting a higher temperature and longer duration when the graphic is a solid color graphic as opposed to a patterned graphic and selecting a lower temperature and shorter duration when the graphic is the patterned graphic as opposed to the solid color graphic. 
     
     
         7 . The method of  claim 1 , wherein selecting the pressure, temperature and duration based on the texture of the outsole plate includes selecting a longer duration when the outsole plate is matted as opposed to glossy and selecting a shorter duration when the outsole plate is glossy as opposed to matted. 
     
     
         8 . The method of  claim 1 , wherein selecting the pressure, temperature and duration based on the height difference of the cleat members on the outsole plate includes selecting one or more of a higher temperature and longer duration as a vertical height difference between two or more cleat members of the plurality of cleat members on the outsole plate increases. 
     
     
         9 . The method of  claim 1 , wherein selecting the pressure, temperature and duration based on the material of the outsole plate includes selecting one or more of a higher temperature and longer duration as a hardness of the material of the outsole plate decreases. 
     
     
         10 . The method of  claim 1 , wherein the cleat members of the plurality of cleat members have a vertical height in a range of 40-80 mm. 
     
     
         11 . The method of  claim 10 , wherein the plurality of cleat members includes at least two cleat members having a different height. 
     
     
         12 . The method of  claim 1 , wherein the plurality of cleat members includes at least two cleat members having a different shape. 
     
     
         13 . A method for forming a graphic on an outsole for an article of footwear, comprising:
 preparing an outsole plate for the outsole for graphic sublimation, the outsole plate comprising a plurality of cleat members that protrude outwardly from a base surface of the outsole plate, and mounting the outsole plate within a tray;   positioning a printed film comprising a graphic over the outsole plate and the tray to form a tray assembly and positioning the tray assembly inside a vacuum-sublimation oven;   selecting a temperature from within a range of 110 to 140 degrees Celsius and a cycle time from within a range of 300 to 500 seconds for transferring the graphic on the printed film to the outsole plate; and   activating the vacuum-sublimation oven to transfer the graphic on the printed film to the outsole plate at the selected temperature and cycle time, and at a pressure of −0.1 MPa such that the graphic is formed over at least a first portion of the base surface and the plurality of cleat members.   
     
     
         14 . The method of  claim 13 , wherein selecting the temperature and cycle time includes selecting a higher temperature and longer cycle time for a solid color graphic and selecting a lower temperature and shorter cycle time for a patterned graphic. 
     
     
         15 . The method of  claim 13 , wherein selecting the temperature and cycle time includes selecting a longer cycle time and first temperature within the range when the outsole plate is matted and selecting a shorter cycle time and the first temperature when the outsole plate is glossy. 
     
     
         16 . The method of  claim 13 , wherein selecting the temperature and cycle time includes selecting one or more of a higher temperature and longer cycle time as a vertical height difference between two or more cleat members of the plurality of cleat members on the outsole plate increases. 
     
     
         17 . The method of  claim 13 , wherein selecting the temperature and cycle time includes selecting one or more of a higher temperature and longer cycle time as a hardness of a material of the outsole plate decreases. 
     
     
         18 . The method of  claim 13 , wherein the plurality of cleat members includes at least two cleat members having a different height within a range of 40-80 mm. 
     
     
         19 . A vacuum-sublimation system comprising:
 a tray comprising an outsole-mounting portion and a rim disposed above the outsole-mounting portion, wherein the outsole-mounting portion is shaped to receive an outsole plate comprising a plurality of cleat members thereon;   a frame configured to fit and seal against the rim; and   a vacuum-sublimation oven comprising a drawer configured to receive the tray therein and one or more controls for setting a pressure, temperature, and time duration for vacuum-sublimation.   
     
     
         20 . The vacuum-sublimation system of  claim 19 , wherein the rim is configured to receive a printed film comprising a graphic to be sublimated onto the outsole plate thereon, and wherein the frame is configured to fit and seal against the rim, thereby sandwiching edges of the printed film between the rim and the frame.