Article of footwear incorporating an embroidered element, and related methods of manufacture

An article of footwear having an upper and a sole structure secured to the upper, the upper comprising a first upper element comprising:

• a base layer having an interior surface and an opposite exterior surface, the interior surface facing an interior of the article of footwear;
• a first structural layer comprising a plurality of first discrete, separate embroidered elongate elements extending over at least a portion of the exterior surface of the base layer, wherein adjacent elongate structural elements define a gap therebetween and wherein the first embroidered elongate elements each comprise a plurality of zig-zag stitches extending across a first longitudinal direction, wherein a span of each zig-zag stitch defines a transverse width of the elongate structural element, a zig-zag stitch density, and a stitch angle for each zig-zag stitch with respect to the first longitudinal direction, and wherein (i) the first longitudinal direction and the transverse width of at least one of the first embroidered elongate elements varies smoothly over a length of at least a first section of the first embroidered elongate element, (ii) at least a portion of at least one first embroidered elongate element is at least partially fused to the exterior surface of the base layer through the application of at least one of heat and pressure, and (iii) at least one of the first embroidered elongate structural elements comprises a first distal end and a second distal end each extending to a lower edge of the upper, and (iv) the first longitudinal direction of at least two adjacent elongate structural elements extends in a parallel direction for a first portion of their lengths and in a non-parallel direction for a second portion of their lengths;
• and
• a second structural layer comprising a plurality of second embroidered elongate elements extending over at least a portion of the exterior surface of the base layer, wherein the second embroidered elongate elements each comprise a plurality of zig-zag stitches extending across a second longitudinal direction, wherein a span of each zig-zag stitch defines a transverse width of the elongate structural element, a zig-zag stitch density, and a stitch angle for each zig-zag stitch with respect to the second longitudinal direction, and wherein:
• (i) at least one of the second longitudinal direction and the transverse width of at least one of the second embroidered elongate elements varies smoothly over a length of at least a first section of the second embroidered elongate element, (ii) at least a portion of at least one second embroidered elongate element is at least partially fused to the exterior surface of the base layer through the application of at least one of heat and pressure, and (iii) an arrangement of the second embroidered elongate elements differs from an arrangement of the first embroidered elongate elements.