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`US 20050193592Al
`
`(19) United States
`(12) Patent Application Publication
`Dua et al.
`
`(10) Pub. No.: US 2005/0193592 Al
`Sep. 8, 2005
`(43) Pub. Date:
`
`(54) ARTICLE OF FOOTWEAR HAVING A
`TEXTILE UPPER
`
`(75)
`
`Inventors: Bhupesh Dua, Portland, OR (US);
`Edward Nathaniel Thomas, Portland,
`OR (US)
`
`Correspondence Address:
`BANNER & WITCOFF, LTD.
`1001 G STREET, N. W.
`WASHINGTON, DC 20001-4597 (US)
`
`{73) Assignee: NIKE, Inc., Beaverton, OR
`
`(21) Appl. No.:
`
`10/791,289
`
`(22) Filed:
`
`Mar. 3, 2004
`
`Publication Classification
`
`(51)
`
`Int. Cl.7
`
`..................................................... A43B 23/00
`
`(52) U.S. Cl.
`
`. ................................................................. 36/45
`
`(57)
`
`ABSTRACT
`
`An article of footwear and a method of manufacturing the
`article of footwear are disclosed. The footwear may include
`an upper and a sole structure. The upper incorporates a
`textile element with edges that are joined together to define
`at least a portion of a void for receiving a foot. The textile
`element may also have a first area and a second area with a
`unitary construction. The first area is formed of a first stitch
`configuration, and the second area is formed of a second
`stitch configuration that is different from the first stitch
`configuration to impart varying textures to a surface of the
`textile element. Various warp knitting or weft knitting pro(cid:173)
`cesses may be utilized to form the textile element.
`
`40 11
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`
`Skechers EX1014-p.1
`Skechers v Nike
`
`

`

`Patent Application Publication Sep. 8, 2005 Sheet 1 of 12
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`Skechers EX1014-p.5
`Skechers v Nike
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`

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`Skechers EX1014-p.6
`Skechers v Nike
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`

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`Patent Application Publication Sep. 8, 2005 Sheet 6 of 12
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`Skechers EX1014-p.7
`Skechers v Nike
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`

`

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`Skechers v Nike
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`

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`Patent Application Publication Sep. 8, 2005 Sheet 8 of 12
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`Skechers EX1014-p.9
`Skechers v Nike
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`

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`Patent Application Publication Sep. 8, 2005 Sheet 9 of 12
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`Skechers EX1014-p.10
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`

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`Patent Application Publication Sep. 8, 2005 Sheet 10 of 12
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`Skechers v Nike
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`Patent Application Publication Sep. 8, 2005 Sheet 12 of 12
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`Skechers EX1014-p.13
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`US 2005/0193592 Al
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`Sep.8,2005
`
`1
`
`ARTICLE OF FOOTWEAR HAVING A TEXTILE
`UPPER
`
`BACKGROUND OF THE INVENTION
`
`[0001] 1. Field of the Invention
`[0002] The present invention relates to footwear. The
`invention concerns, more particularly, an article of footwear
`incorporating an upper that is at least partially formed from
`a textile material.
`[0003] 2. Description of Background Art
`[0004] Conventional articles of athletic footwear include
`two primary elements, an upper and a sole structure. The
`upper provides a covering for the foot that securely receives
`and positions the foot with respect to the sole structure. In
`addition, the upper may have a configuration that protects
`the foot and provides ventilation, thereby cooling the foot
`and removing perspiration. The sole structure is secured to
`a lower surface of the upper and is generally positioned
`between the foot and the ground. In addition to attenuating
`ground reaction forces and absorbing energy (i.e., imparting
`cushioning), the sole structure may provide traction and
`control potentially harmful foot motion, such as over prona(cid:173)
`tion. Accordingly, the upper and the sole structure operate
`cooperatively to provide a comfortable structure that is
`suited for a wide variety of ambulatory activities, such as
`walking and running. The general features and configuration
`of the conventional upper are discussed in greater detail
`below.
`[0005] The upper forms a void on the interior of the
`footwear for receiving the foot. The void has the general
`shape of the foot, and access to the void is provided by an
`ankle opening. Accordingly, the upper extends over the
`instep and toe areas of the foot, along the medial and lateral
`sides of the foot, and around the heel area of the foot. A
`lacing system is often incorporated into the upper to selec(cid:173)
`tively increase the size of the ankle opening and permit the
`wearer to modify certain dimensions of the upper, particu(cid:173)
`larly girth, to accommodate feet with varying proportions. In
`addition, the upper may include a tongue that extends under
`the lacing system to enhance the comfort of the footwear,
`and the upper may include a heel counter to limit movement
`of the heel.
`[0006] Various materials may be utilized in manufacturing
`the upper. The upper of an article of athletic footwear, for
`example, may be formed from multiple material layers that
`include an exterior layer, an intermediate layer, and an
`interior layer. The materials forming the exterior layer of the
`upper may be selected based upon the properties of wear(cid:173)
`resistance, flexibility, and air-permeability, for example.
`With regard to the exterior layer, the toe area and the heel
`area may be formed of leather, synthetic leather, or a rubber
`material to impart a relatively high degree of wear-resis(cid:173)
`tance. Leather, synthetic leather, and rubber materials may
`not exhibit the desired degree of flexibility and air-perme(cid:173)
`ability. Accordingly, various other areas of the exterior layer
`of the upper may be formed from a synthetic or natural
`textile. The exterior layer of the upper may be formed,
`therefore, from numerous material elements that each impart
`different properties to specific portions of the upper.
`[0007] An intermediate layer of the upper may be formed
`from a lightweight polymer foam material that provides
`cushioning and protects the foot from objects that may
`contact the upper. Similarly, an interior layer of the upper
`may be formed of a moisture-wicking textile that removes
`
`perspiration from the area immediately surrounding the foot.
`In some articles of athletic footwear, the various layers may
`be joined with an adhesive, and stitching may be utilized to
`join elements within a single layer or to reinforce specific
`areas of the upper.
`[0008] Although the materials selected for the upper vary
`significantly, textile materials often form at least a portion of
`the exterior layer and interior layer. A textile may be defined
`as any manufacture from fibers, filaments, or yarns charac(cid:173)
`terized by flexibility, fineness, and a high ratio of length to
`thickness. Textiles generally fall into two categories. The
`first category includes textiles produced directly from webs
`of filaments or fibers by randomly interlocking to construct
`non-woven fabrics and felts. The second category includes
`textiles formed through a mechanical manipulation of yarn,
`thereby producing a woven fabric, for example.
`[0009] Yarn is the raw material utilized to form textiles in
`the second category. In general, yarn is defined as an
`assembly having a substantial length and relatively small
`cross-section that is formed of at least one filament or a
`plurality of fibers. Fibers have a relatively short length and
`require spinning or twisting processes to produce a yarn of
`suitable length for use in textiles. Common examples of
`fibers are cotton and wool. Filaments, however, have an
`indefinite length and may merely be combined with other
`filaments to produce a yarn suitable for use in textiles.
`Modern filaments include a plurality of synthetic materials
`such as rayon, nylon, polyester, and polyacrylic, with silk
`being the primary, naturally-occurring exception. Yarn may
`be formed of a single filament, which is conventionally
`referred to as a monofilament yarn, or a plurality of indi(cid:173)
`vidual filaments grouped together. Yarn may also include
`separate filaments formed of different materials, or the yarn
`may include filaments that are each formed of two or more
`different materials. Similar concepts also apply to yarns
`formed from fibers. Accordingly, yarns may have a variety
`of configurations that generally conform to the definition
`provided above.
`[0010] The various techniques for mechanically manipu(cid:173)
`lating yarn into a textile include interweaving, intertwining
`and twisting, and interlooping. Interweaving is the intersec(cid:173)
`tion of two yarns that cross and interweave at right angles to
`each other. The yarns utilized in interweaving are conven(cid:173)
`tionally referred to as warp and weft. Intertwining and
`twisting encompasses procedures such as braiding and knot(cid:173)
`ting where yarns intertwine with each other to form a textile.
`Interlooping involves the formation of a plurality of columns
`of intermeshed loops, with knitting being the most common
`method of interlooping.
`[0011] The textiles utilized in footwear uppers generally
`provide a lightweight, air-permeable structure that is flexible
`and comfortably receives the foot. In order to impart other
`properties to the footwear, including durability and stretch(cid:173)
`resistance, additional materials are commonly combined
`with the textile, including leather, synthetic leather, or
`rubber, for example. With regard to durability, U.S. Pat. No.
`4,447,967 to Zaino discloses an upper formed of a textile
`material that has a polymer material injected into specific
`zones to reinforce the zones against abrasion or other forms
`of wear. Regarding stretch resistance, U.S. Pat. No. 4,813,
`158 to Brown and U.S. Pat. No. 4,756,098 to Boggia both
`disclose a substantially inextensible material that is secured
`to the upper, thereby limiting the degree of stretch in specific
`portions of the upper.
`[0012] From the perspective of manufacturing, utilizing
`multiple materials to impart different properties to an article
`
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`Sep.8,2005
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`2
`
`of footwear may be an inefficient practice. For example, the
`various materials utilized in a conventional upper are not
`generally obtained from a single supplier. Accordingly, a
`manufacturing facility must coordinate the receipt of spe(cid:173)
`cific quantities of materials with multiple suppliers that may
`have distinct business practices or may be located in differ(cid:173)
`ent regions or countries. The various materials may also
`require additional machinery or different assembly line
`techniques to cut or otherwise prepare the material for
`incorporation into the footwear. In addition, incorporating
`separate materials into an upper may involve a plurality of
`distinct manufacturing steps requiring multiple individuals.
`Employing multiple materials, in addition to textiles, may
`also detract from the breathability of footwear. Leather,
`synthetic leather, or rubber, for example, are not generally
`permeable to air. Accordingly, positioning leather, synthetic
`leather, or rubber on the exterior of the upper may inhibit air
`flow through the upper, thereby increasing the amount of
`perspiration, water vapor, and heat trapped within the upper
`and around the foot.
`
`SUMMARY OF THE INVENTION
`
`[0013] The present invention is an upper for an article of
`footwear, the upper incorporating a textile element formed
`with a knitting machine, for example. In one aspect of the
`invention, the textile element has edges that are joined
`together to define at least a portion of a void for receiving a
`foot. In another aspect of the invention, the textile element
`has a first area and a second area of unitary construction. The
`first area is formed of a first stitch configuration, and the
`second area is formed of a second stitch configuration that
`is different from the first stitch configuration to impart
`varying textures to a surface of the textile element. The
`knitting machine may have a configuration that forms the
`textile element through either warp knitting or weft knitting.
`
`[0014] Another aspect of the invention involves a method
`of manufacturing an article of footwear. The method
`includes a step of mechanically-manipulating a yarn with a
`circular knitting machine, for example, to form a cylindrical
`textile structure. In addition, the method involves removing
`at least one textile element from the textile structure, and
`incorporating the textile element into an upper of the article
`of footwear.
`
`[0015]
`In another aspect of the invention, an article of
`footwear has an upper and a sole structure secured to the
`upper. The upper incorporates a textile element formed with
`a knitting machine. The textile element is removed from a
`textile structure that includes an outline of the textile ele(cid:173)
`ment, and the textile element has edges that are joined
`together to define at least a portion of a void for receiving a
`foot.
`
`[0016] The advantages and features of novelty character(cid:173)
`izing the present invention are pointed out with particularity
`in the appended claims. To gain an improved understanding
`of the advantages and features of novelty, however, refer(cid:173)
`ence may be made to the following descriptive matter and
`accompanying drawings that describe and illustrate various
`embodiments and concepts related to the invention.
`
`DESCRIPTION OF THE DRAWINGS
`
`[0017] The foregoing Summary of the Invention, as well
`as the following Detailed Description of the Invention, will
`be better understood when read in conjunction with the
`accompanying drawings.
`
`[0018] FIG. 1 is a lateral elevational view of an article of
`footwear having an upper in accordance with the present
`invention.
`[0019] FIG. 2 is a lateral elevational view of the upper.
`[0020] FIG. 3 is a top plan view of the upper.
`[0021] FIG. 4 is a rear elevational view of the upper.
`[0022] FIG. 5 is a bottom plan view of the upper.
`[0023] FIG. 6 is a first cross-sectional view of the upper,
`as defined by section line 6-6 in FIG. 2.
`[0024] FIG. 7 is a second cross-sectional view of the
`upper, as defined by section line 7-7 in FIG. 2.
`[0025] FIG. 8 is a plan view of a textile element that forms
`at least a portion of the upper.
`[0026] FIG. 9 is a perspective view of a textile structure
`that incorporates two of the textile element.
`[0027] FIG. 10 is a plan view of another textile element.
`[0028] FIG. 11 is a plan view of yet another textile
`element.
`[0029] FIG. 12 is a lateral elevational view of another
`article of footwear having an upper in accordance with the
`present invention.
`[0030] FIG. 13 is a lateral elevational view of yet another
`article of footwear having an upper in accordance with the
`present invention.
`[0031] FIG. 14 is a cross-sectional view of the footwear
`depicted in FIG. 13, as defined by section line 14-14.
`
`DETAILED DESCRIPTION OF THE
`INVENTION
`
`[0032] The following discussion and accompanying fig(cid:173)
`ures disclose an article of footwear 10 and a method of
`manufacturing footwear 10, or components thereof, in
`accordance with the present invention. Footwear 10 is
`depicted in the figures and discussed below as having a
`configuration that is suitable for athletic activities, particu(cid:173)
`larly running. The concepts disclosed with respect to foot(cid:173)
`wear 10 may, however, be applied to footwear styles that are
`specifically designed for a variety of other athletic activities,
`including basketball, baseball, football, soccer, walking, and
`hiking, for example, and may also be applied to various
`non-athletic footwear styles. Accordingly, one skilled in the
`relevant art will recognize that the concepts disclosed herein
`may be applied to a wide range of footwear styles and are not
`limited to the specific embodiments discussed below and
`depicted in the figures.
`[0033] The primary elements of footwear 10 are depicted
`in FIG. 1 as being a sole structure 20 and an upper 30. Sole
`structure 20 is secured to a lower portion of upper 30 and
`provides a durable, wear-resistant component that imparts
`cushioning as footwear 10 impacts the ground. Upper 30 is
`at least partially formed from a textile element 40 that
`defines an interior void for comfortably receiving a foot and
`securing a position of the foot relative to sole structure 20.
`Various edges of textile element 40 are then secured together
`to form the shape of upper 30. In some embodiments, textile
`element 40 may form substantially all of upper 30, or textile
`element 40 may only be a portion of an upper.
`[0034] Sole structure 20 has a generally conventional
`configuration that includes a midsole 21 and an outsole 22.
`
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`Sep.8,2005
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`3
`
`Midsole 21 is secured to a lower portion of upper 30 and is
`formed of a polymer foam material, such as ethylvinylac(cid:173)
`etate or polyurethane. Accordingly, midsole 21 attenuates
`ground reaction forces and absorbs energy (i.e., provides
`cushioning) as sole structure 20 impacts the ground. To
`enhance the force attenuation and energy absorption char(cid:173)
`acteristics of sole structure 20, midsole 21 may incorporate
`a fluid-filled bladder, as disclosed in U.S. Pat. Nos. 4,183,
`156 and 4,219,945 to Rudy. Alternately or in combination,
`midsole 21 may incorporate a plurality of discrete, columnar
`support elements, as disclosed in U.S. Pat. Nos. 5,343,639
`and 5,353,523 to Kilgore et al. Outsole 22 is secured to a
`lower surface of midsole 21 and may be formed from carbon
`black rubber compound to provide a durable, wear-resistant
`surface for engaging the ground. Outsole 22 may also
`incorporate a textured lower surface to enhance the traction
`characteristics of footwear 10. In addition, footwear 10 may
`include an insole (not depicted), which is a relatively thin,
`cushioning member located within upper 30 and adjacent to
`a plantar surface of the foot for enhancing the comfort of
`footwear 10.
`
`[0035] Sole structure 20 is described above as having the
`elements of a conventional sole structure for athletic foot(cid:173)
`wear. Other footwear styles, including, dress shoes and
`boots, for example, may have other types of conventional
`sole structures specifically tailored for use with the respec(cid:173)
`tive types of footwear. In addition to a conventional con(cid:173)
`figuration, however, sole structure 20 may also exhibit a
`unique, non-conventional structure. Accordingly, the par(cid:173)
`ticular configuration of sole structure 20 may vary signifi(cid:173)
`cantly within the scope of the present invention to include a
`wide range of configurations, whether conventional or non(cid:173)
`conventional.
`
`[0036] Upper 30 is depicted in FIGS. 2-7 as having a
`lateral region 31, an opposite medial region 32, an instep
`region 33, a lower region 34, and a heel region 35. Lateral
`region 31 extends through a longitudinal length of footwear
`10 and is generally configured to contact and cover a lateral
`side of the foot. Medial region 32 has a similar configuration
`that generally corresponds with a medial side of the foot.
`Instep region 33 is positioned between lateral region 31 and
`medial region 32, and instep region 33 extends over an
`instep area of the foot. Lower region 34 forms a bottom
`surface of upper 30 and also extends through the longitudi(cid:173)
`nal length of footwear 10. Heel region 35 forms a rear
`portion of upper 30 and is generally configured to contact
`and cover a heel area of the foot. In addition, lateral region
`31, medial region 32, instep region 33, and heel region 35
`cooperatively define an ankle opening 36 for providing the
`foot with access to the void within upper 30.
`
`[0037] Upper 30 is at least partially formed from textile
`element 40, which forms regions 31-35, and may also
`include laces or other elements associated with a conven(cid:173)
`tional upper for footwear. Textile element 40 is a single
`material element that is formed to exhibit a unitary (i.e.,
`one-piece) construction, and textile element 40 is formed or
`otherwise shaped to extend around the foot. As depicted in
`FIGS. 2-7, textile element 40 forms both an exterior surface
`and an interior surface of upper 30. Textile element 40 may
`be formed as a part of a larger textile element. Textile
`element 40 is then removed from the larger textile element
`and various edges of textile element 40 are secured together
`to form the shape of upper 30. A plurality of seams 51-54 are
`formed, therefore, when joining the edges of the textile
`element. Seam 51 extends along the longitudinal length of
`lower region 34 and is centrally-located with respect to
`
`lateral region 31 and medial region 32. Seam 52 is also
`centrally-located and extends upward along heel region 35.
`A seam 53 is positioned in a forefoot area of upper 30 and
`joins a portion of lower region 34 with both of lateral region
`31 and medial region 32. In addition, a seam 54 is positioned
`in a rear area of upper 30 and joins a portion of lower region
`34 with heel region 35.
`[0038] Textile element 40 exhibits the general shape
`depicted in FIG. 8 prior to the formation of seams 51-54.
`Following formation of seams 51-54, however, textile ele(cid:173)
`ment 40 exhibits the shape of upper 30 depicted in FIGS.
`2-7. Seams 51-54 are formed by securing various edges of
`textile element 40 together. More specifically, (1) seam 51 is
`formed by securing an edge 41a with an edge 41b; (2) seam
`52 is formed by securing an edge 42a with an edge 42b; (3)
`a first portion of seam 53 is formed by securing an edge 43a
`with an edge 43b ( 4) a second portion of seam 53 is formed
`by securing an edge 43c with an edge 43d; (5) a first portion
`of seam 54 is formed by securing an edge 44a with an edge
`44b; and (6) a second portion of seam 54 is formed by
`securing an edge 44c with an edge 44d. Referring to FIG. 8,
`the positions of regions 31-35 and ankle opening 36 are
`identified to provide a frame of reference relating to the
`various portions of textile element 40.
`[0039]
`In order to join edges 41a and 41b to form seam 51,
`textile element 40 is folded or otherwise overlapped such
`that edge 41a is placed adjacent to edge 41b. Stitching, an
`adhesive, or heat bonding, for example, is then utilized to
`secure edge 41a and edge 41b. Textile element 40, as
`depicted in FIG. 8, has a generally planar configuration.
`Upon the formation of seam 51, however, one portion of
`textile element 40 overlaps the other portion of textile
`element 40. The volume between the overlapping portions
`effectively forms a portion of the void within upper 30 for
`receiving the foot.
`[0040] The folding or overlapping of textile element 40 to
`form seam 51 places edge 42a adjacent to edge 42b, which
`facilitates the formation of seam 52. With reference to FIG.
`8, an edge 45 forms a generally u-shaped area in textile
`element 40. Upon the joining of edges 42a and 42b to form
`seam 52, the u-shaped area becomes an aperture in textile
`element 40 and effectively forms ankle opening 36. Each of
`edges 43a-43d and edges 44a-44d are formed from a gen(cid:173)
`erally v-shaped area of textile element 40. Accordingly,
`seams 53 and 54 may be formed by closing the v-shaped
`areas and securing the various edges together.
`[0041] Following the formation of each of seams 51-54,
`the manufacturing of upper 30 is essentially complete.
`Various finishing steps may be performed, such as reinforc(cid:173)
`ing ankle opening 36, for example. Upper 30 (i.e., textile
`element 40) is then secured to sole structure 20, with an
`adhesive, for example. The insole is then placed into the
`void within upper 30 and adjacent to lower region 34. In
`some embodiments, various reinforcing members may be
`added to the exterior or interior surface of upper 20 in order
`to limit the degree of stretch in upper 20 or provide enhanced
`wear-resistance. In addition, a lacing system may be added
`to provide adjustability.
`
`[0042] Textile element 40 is a single material element with
`a unitary construction, as discussed above. As defined for
`purposes of the present invention, unitary construction is
`intended to express a configuration wherein portions of a
`textile element are not joined together by seams or other
`connections, as depicted with textile element 40 in FIG. 8.
`Although the various edges 41a-44d are joined together to
`
`Skechers EX1014-p.16
`Skechers v Nike
`
`

`

`US 2005/0193592 Al
`
`Sep.8,2005
`
`4
`
`form seams 51-54, the various portions of textile element 40
`are formed as an unitary element without seams, as dis(cid:173)
`cussed below.
`[0043] Textile element 40 is primarily formed from one or
`more yarns that are mechanically-manipulated through
`either an interweaving, intertwining and twisting, or inter(cid:173)
`looping process, for example. As discussed in the Back(cid:173)
`ground of the Invention section above, interweaving is the
`intersection of two yarns that cross and interweave at right
`angles to each other. The yarns utilized in interweaving are
`conventionally referred to as warp and weft. Intertwining
`and twisting encompasses procedures such as braiding and
`knotting where yarns intertwine with each other to form a
`textile. Interlooping involves the formation of a plurality of
`columns of intermeshed loops, with knitting being the most
`common method of interlooping. Textile element 40 may,
`therefore, be formed from one of these processes for manu(cid:173)
`facturing a textile.
`[0044] A variety of mechanical processes have been devel(cid:173)
`oped to manufacture a textile. In general, the mechanical
`processes may be classified as either warp knitting or weft
`knitting. With regard to warp knitting, various specific
`sub-types that may be utilized to manufacture a textile
`include tricot, raschel, and double needle-bar raschel (which
`further includes jacquard double needle-bar raschel). With
`regard to weft knitting, various specific sub-types that may
`be utilized to manufacture a textile include circular knitting
`and flat knitting. Various types of circular knitting include
`sock knitting (narrow tube), body garment (seamless or wide
`tube), and jacquard.
`[0045] Textile element 40 may be formed through any of
`the mechanical processes discussed above. Accordingly,
`textile element 40 may be formed on either a warp knitting
`machine or a weft knitting machine. One suitable knitting
`machine for forming textile element 40 is a wide-tube
`circular knit jacquard machine. Another suitable knitting
`machine for forming textile element 40 is a wide-tube
`circular knitting machine that is produced in the Lonati
`Group by Santoni S.p.A. of Italy under the SM8 TOPl
`model number. This Santoni S.p.A. wide-tube circular knit(cid:173)
`ting machine may form a textile structure having a diameter
`that ranges from 10 inches to 20 inches, with 8 feeds for each
`diameter. The machine exhibits a maximum 140 revolutions
`per minute for 10 inch diameters, and a maximum 120
`revolutions per minute for 13 inch diameters. Furthermore,
`the machine gauge is variable between 16, 22, 24, 26, 28,
`and 32 needles per inch, and is suitable for various needle
`gauges ranging from 48 to 75.
`[0046] A wide-tube circular knitting machine, as produced
`by Santoni S.p.A., forms a generally cylindrical textile
`structure and is capable of forming various types of stitches
`within a single textile structure. In general, the wide-tube
`circular knitting machine may be programmed to alter the
`design on the textile structure through needle selection. That
`is, the type of stitch that is formed at each location on the
`textile structure may be selected by programming the wide(cid:173)
`tube circular knitting machine such that specific needles
`either accept or do not accept yarn at each stitch location. In
`this manner, various patterns, textures, or designs may be
`selectively and purposefully imparted to the textile structure.
`
`[0047] An example of a textile structure 60 that may be
`formed with a wide-tube circular knitting machine is
`depicted in FIG. 9. Textile structure 60 has a generally
`cylindrical configuration, and the types of stitches vary
`throughout textile structure 60 so that a pattern is formed
`
`with the outline of textile element 40. That is, differences in
`the stitches within textile structure 60 form an outline with
`the shape and proportions of textile element 40.
`
`[0048] The Santoni S.p.A. wide-tube circular knitting
`machine may form a textile structure having a diameter that
`ranges from 10 inches to 16 inches, as discussed above.
`Assuming that textile structure 60 exhibits a diameter of 10
`inches, then the circumference of textile structure 60 is
`approximately 31 inches. In many circumstances, the total
`width of textile element 40 will be approximately 12 inches,
`depending upon the size of footwear 10. The outlines for at
`least two textile elements 40 may, therefore, be formed on
`textile structure 60. Referring to FIG. 9, the outline of textile
`element 40 is depicted on a front portion of textile structure
`60, and the outline of another textile element 40 is depicted
`on a rear portion of textile structure 60. Accordingly, a first
`textile element 40 and a second textile element 40 may be
`simultaneously formed in a single textile structure 60. As the
`diameter of textile element 60 is increased or the width of
`textile element 40 decreases, however, an even greater
`number of textile elements 40 may be outlined on textile
`structure 60.
`
`[0049] Textile structure 60 may be formed with a wide(cid:173)
`tube circular knitting machine, as discussed above. The
`types of stitches that form textile structure 60 may be varied
`to form an outline of one or more textile elements 40 on
`textile structure 60. That is, the wide-tube circular knitting
`machine may be programmed to form different types of
`stitches in textile structure 60 so as to outline one or more
`textile elements 40. Each textile element 40 is then removed
`from textile structure 60 with a die-cutting, laser-cutting, or
`other conventional cutting operation. Once textile element
`40 is removed from textile structure 60, seams 51-54 may be
`formed and textile element 40 may be incorporated into
`footwear 10.
`
`[0050] The yarn forming textile element 40 may be gen(cid:173)
`erally defined as an assembly having a substantial length and
`relatively small cross-section that is formed of at least one
`filament or a plurality of fibers. Fibers have a relatively short
`length and require spinning or twisting processes to produce
`a yarn of suitable length for use in an interlooping process.
`Common examples of fibers are cotton and wool. Filaments,
`however, have an indefinite length and may merely be
`combined with other filaments to produce a yarn suitable for
`use in an interlooping process. Modern filaments include a
`plurality of synthetic materials such as rayon, nylon, poly(cid:173)
`ester, and acrylic, with silk being the primary, naturally(cid:173)
`occurring exception. Yarn may be formed of a single fila(cid:173)
`ment (conventionally referred to as a monofilament yarn) or
`a plurality of individual filaments. Yarn may also be formed
`of separate filaments formed of