Article with integral loops and method of manufacturing

Abstract

A method of manufacturing an article may include loading a soluble bobbin thread into an embroidery machine and then driving a needle thread through a base sheet with a needle of the embroidery machine according to a programmed first pattern that provides a series of loops of the needle thread extending outward from a bobbin side of the base sheet. The method may further include bonding the needle thread to a needle side of the base sheet opposite from the bobbin side. A spacer layer may be disposed at the bobbin side of the base sheet, and may be removed after the needle thread is bonded to the base sheet. The loops may be loops of a hook-and-loop fastener or ball control features in various articles manufactured according to the method.

What is claimed is: 
     
         1 . An article comprising:
 a base sheet; and   a thread configured as a series of loops, the series of loops configured as a loop portion of a hook-and-loop fastener and arranged in a first pattern and extending through the base sheet and outward from a first side of the base sheet;   wherein the thread is bonded to a second side of the base sheet opposite from the first side of the base sheet;   wherein the article is a footwear upper, apparel, or a carry bag.   
     
     
         2 . The article of  claim 1 , wherein the thread is a fusible thread and is directly fused to the second side of the base sheet. 
     
     
         3 . The article of  claim 1 , further comprising:
 a meltable bonding layer disposed against the second side of the base sheet;   wherein the thread extends through the meltable bonding layer; and   wherein the thread is bonded to the second side of the base sheet by the meltable bonding layer.   
     
     
         4 . The article of  claim 3 , wherein the meltable bonding layer comprises thermoplastic polyurethane. 
     
     
         5 . The article of  claim 1 , wherein the article is the footwear upper;
 wherein the base sheet is a side panel of the footwear upper; and   wherein the series of loops extends outward of an exterior of the side panel and is configured as a ball control feature.   
     
     
         6 . The article of  claim 1 , wherein the article is the footwear upper;
 wherein the base sheet is a strap of the footwear upper; and   wherein the series of loops is configured as a strap fastener.   
     
     
         7 . The article of  claim 1 , wherein the article is the apparel;
 wherein the apparel includes a pocket; and   wherein the series of loops is configured as a fastener on a flap of the pocket.   
     
     
         8 . The article of  claim 1 , wherein the article is the carry bag;
 wherein the base sheet is a strap of the carry bag; and   wherein the series of loops is configured as a strap fastener.   
     
     
         9 . The article of  claim 1 , wherein the article is the carry bag;
 wherein the base sheet is a panel of the carry bag that defines a cavity; and   wherein the series of loops is configured as a fastener on the panel.   
     
     
         10 . The article of  claim 1 , wherein the thread has a thickness from about 0.05 millimeters to about 0.1 millimeters. 
     
     
         11 . The article of  claim 1 , wherein the series of loops includes a first group of loops that have a first density and a second group of loops that have a second density different from the first density. 
     
     
         12 . The article of  claim 1 , wherein the series of loops includes a first set of loops that have a first color and a second set of loops that have a second color different from the first color. 
     
     
         13 . The article of  claim 12 , wherein the series of loops includes a third set of the loops disposed between the first set of loops and the second set of loops; and
 wherein the third set of the loops has a color gradient that changes from the first color to the second color.   
     
     
         14 . The article of  claim 13 , wherein the thread is a first color thread at the first set of loops, a second color thread at the second set of loops, and a mixture of both the first color thread and the second color thread at the third set of loops.