A method of manufacturing an article may include positioning a first textile sheet against a second textile sheet and reciprocating a single needle of an embroidery machine through the first textile sheet and the second textile sheet, the needle forcing fibers of the second textile sheet through the first textile sheet. The fibers may have terminal ends extending outward of an exterior side of the first textile sheet through which the fibers are forced. A method may include forcing fibers from a second side to an opposite side of a single textile sheet to create a pattern of the fibers on the opposite side. Various articles such as footwear uppers may be manufactured according to the method.

The invention relates to systems and methods for creating wound material portions for incorporation into an article of footwear. More particularly, one method of manufacturing at least a portion of an upper for an article of footwear, in accordance with the invention, includes the steps of providing a support structure, providing a fiber delivery system, tacking a first end of a first fiber onto the support structure, moving the support structure with respect to the fiber delivery system to wind the first fiber around the support structure, cutting a second end of the first fiber upon positioning of the first fiber onto the support structure, and treating at least a portion of the first fiber to fixedly hold it in a wound arrangement and form a fabric layer for incorporation into an article of footwear.

The present disclosure is directed to articles that include one or more coated fiber(s) (i.e., fiber(s) with a cured coating disposed thereon), where the coating includes a matrix of crosslinked polymers and optionally a colorant (e.g., pigment particles or dye or both). The cured coating is a product of crosslinking a coating composition including uncrosslinked polymers (e.g., a dispersion of uncrosslinked polymers in a carrier, wherein the uncrosslinked polymers are crosslinked to form the matrix of crosslinked polymers). The present disclosure is also directed to articles including the coated fibers, methods of forming the coated fibers and articles, and methods of making articles including the coated fibers.

The present disclosure is directed to articles that include a cured coating that includes a matrix of crosslinked polymers and optionally a colorant (e.g., pigment particles or dye or both). The cured coating can include a matrix of crosslinked polymers. The cured coating is a product of crosslinking a coating composition comprising uncrosslinked polymers (e.g., a dispersion of uncrosslinked polymers in a carrier to form the matrix of crosslinked polymers), wherein the uncrosslinked polymers are crosslinked to form the matrix of crosslinked polymers. The matrix of crosslinked polymers can be elastomeric. The present disclosure is also directed to articles including these bladders, methods of forming these bladders, and methods of making articles including these bladders, where the bladders include the cured coating.

An article of footwear with a knitted component including an upper and an integral knit ankle cuff is provided. The upper and the ankle cuff are formed as a one-piece knit element. The knit element forms a portion of an exterior surface of the upper and an opposite interior surface of the upper, with the interior surface forming a void for receiving a foot. The ankle cuff is formed of unitary knit construction with the upper as a one-piece knit element and extends above a throat area of the upper. The ankle cuff includes malleolus zones on medial and lateral sides to correspond with the ankle bones of a wearer. The knit component further incorporates features to assist with providing entry for a foot of a wear, providing comfort to a wearer, and to assist with orientation of the upper of the article of footwear when being worn.

A method for manufacturing an integral shoe blank is provided. In the method, a reinforcement piece is woven by a flat knitting machine during a weave process, and the reinforcement piece is made unperceivable through a subsequent side overturning step when viewing from an exterior of a shoe. Thus, with the reinforcement piece, structural strength of the shoe blank is reinforced while better comfort is provided to the foot by a shoe manufactured from the shoe blank.

An object of the present invention is to provide a shoe including an upper that is easily conformed to a shape of a last when it is shaped. The shoe includes an upper made of a fiber sheet that includes: a first layer made of knitted fabric or woven fabric that includes yarns having a heat shrinkability and has inner gaps; and a second layer layered on the first layer and made of nonwoven fabric, knitted fabric or woven fabric, and being integrated with the first layer by needle punching.

A shoe may include an upper portion that includes one or more textile (e.g., wool) layers and one or more water-resistant membranes for providing or enhancing water resistance of the shoes. The water-resistant membranes may be positioned between the textile layers to provide or enhance water resistance without affecting the appearance and/or feel of the interior and exterior surfaces of the upper portion. The shoe may include a durable water repellent coating along at least a portion of an exterior surface for water resistance and durability. The shoes described herein may be constructed at least partially using bio-based materials.

An article of footwear with adjustable stiffness is provided. The article of footwear in the form of a snowboard boot is provided with adjustable tensioning systems that are disposed on either side of an inner liner of the snowboard boot. The adjustable tensioning system includes a comb body structure having flex portions made of a plurality of extending fingers with a flexibility that can be controlled by the adjustable tensioning system. Depending on the level of tension applied by the tensioning system, or lack thereof, a range of flex profiles having varying amounts of stiffness are available to the wearer to adjust the overall stiffness of the snowboard boot.

An upper for an article of footwear is provided, having a braided structure comprising a first yarn having a first cross-sectional shape and a second yarn having a second cross-sectional shape different than the first cross-sectional shape. The first cross-sectional shape comprises an outer surface parallel to an inner surface in a rectangular orientation. Additionally, the first yarn is oriented such that at least a portion of the outer surface comprises the first side of the first yarn and at least a portion of the inner surface comprises the second side of the first yarn.