The present invention provides a system and method for the application of a functional thread to secure roving or other fibers to a substrate, thereby forming a precursor to a resultant composite component structure having targeted, enhanced structural reinforcement. The functional thread may be comprised of one or more fibrous filaments or have a monofilament structure. The invention encompasses the sewing of this functional thread at varying stitch densities as function of component stress analysis, the mechanical stresses that the component will be subject to when exposed to the forces and loads associated with its intended use, and at least one physical or mechanical property of a functional thread. This variable stitch density serves to provide targeted, localized mechanical enhancement and reinforcement to the resultant composite structure.

A strip is fastened to an edge of a textile piece by first advancing strip of the ribbon in a direction parallel to the strip of ribbon from a supply. Then a leading end of the strip is gripped a first nip point while advancing additional ribbon from the ribbon supply. The strip is then gripped at a second nip point upstream of the first nip point at a trailing end of the strip. The ribbon is then severed upstream in the strip-travel direction of the second nip point to separate the strip from the ribbon into a sufficient length between the first nip point and the second nip points. The leading or trailing end is then pivoted about at least one pivot axis relative to the other end and positioned near or on the other end, which is then fastened to the edge of the textile piece.

An article of footwear with an upper including a ribbon structure is disclosed. The ribbon structure comprises ribbon sections running in at least two different directions. Ribbon sections are connected at nodes. Between nodes portions of ribbon act like links joining the nodes. The links can be arranged in various geometries, including a rectangular grid and a triaxial grid. The ribbon structure may extend the entire length of the article of footwear, and may extend through a forefoot, midfoot and heel.

A method of manufacturing an upper for an article of footwear includes dispensing ribbon in an overlapping pattern of ribbon sections to form a ribbon structure; and fixedly attaching a first ribbon section to an underlying material with thermal joining.

An article of footwear with an upper including a ribbon structure is disclosed. The ribbon structure comprises ribbon sections running in at least two different directions. Ribbon sections are connected at nodes that may move substantially independently of other nodes. The ribbon structure can provide strength along one of the directions and may simultaneously remain slack in the other direction.

A method of making an article of footwear with an upper including a ribbon structure is disclosed. The method includes laying down ribbon elements in straight and winding sections. The method includes stitching or otherwise attaching the ribbon elements to a backing layer. The method also includes embroidering a periphery of the ribbon structure to tack down any raised portions of the ribbon at the periphery. The method also includes inserting a lace through loops in the ribbon structure.

An article of footwear with an upper including a ribbon structure is disclosed. The ribbon structure comprises ribbon sections running in at least two different directions. Ribbon sections are connected at nodes. Between nodes portions of ribbon act like links joining the nodes. The links can be arranged in various geometries, including a rectangular grid and a triaxial grid. The ribbon structure may extend the entire length of the article of footwear, and may extend through a forefoot, midfoot and heel.

An attachment for a sewing machine to provide simultaneous sewing and sealing of a seam comprises a reel for dispensing a strip of adhesive thermoplastic polymer between fabric members to be sewn. A plurality of heated driven rollers opposed to heated idler rollers having a continuous belt thereover collectively exert heat and pressure on the seam, melting the polymer strip so as to seal the seam. Thread having been treated with adhesive thermoplastic polymer may be employed to seal the punctures in the fabric made by the sewing machine's needle. The driven rollers are driven in synchronization with the operation of the sewing machine, and are engaged with and withdrawn from the seam responsive to operator command.

An attachment for a sewing machine to provide simultaneous sewing and sealing of a seam comprises a reel for dispensing a strip of adhesive thermoplastic polymer between fabric members to be sewn. A plurality of heated driven rollers opposed to heated idler rollers having a continuous belt thereover collectively exert heat and pressure on the seam, melting the polymer strip so as to seal the seam. Thread having been treated with adhesive thermoplastic polymer may be employed to seal the punctures in the fabric made by the sewing machine's needle. The driven rollers are driven in synchronization with the operation of the sewing machine, and are engaged with and withdrawn from the seam responsive to operator command.

A method and related apparatus for assembling a fabric strip to a knitted article. The method includes the steps of loading a knitted article onto a loading form, wrapping at least an end portion of the knitted article so that an open end thereof is accessible, loading a fabric strip onto loading members, and wrapping it thereon so that a first welt is accessible. Additionally, the method includes mutually positioning the loading form and the loading members by aligning the loading form with respect to the loading members, introducing the loading form into an inner space of the loading members so that the fabric strip surrounds outside the end portion of the knitted article, and letting the first welt overlap and match the open border.