Article with integral loops and method of manufacturing

A method of manufacturing an article, the method comprising:

• disposing one or more first spacer layers at a bobbin side of a first base sheet so that an inner side of the one or more first spacer layers is at the bobbin side of the first base sheet;
• wherein the one or more first spacer layers are a first number of spacer layers and have a first total height;
• driving a first needle thread through both the first base sheet and the one or more first spacer layers with a needle of an embroidery machine according to a programmed first pattern that provides a first series of loops of the first needle thread that extends outward from the bobbin side of the first base sheet through the one or more first spacer layers and engages with a first bobbin thread disposed at an outer side of the one or more first spacer layers;
• bonding the first needle thread to a needle side of the first base sheet opposite from the bobbin side of the first base sheet;
• removing the first bobbin thread;
• moving the one or more first spacer layers away from the first base sheet to slide the one or more first spacer layers off of the first series of loops;
• disposing one or more second spacer layers that are a second number of spacer layers and have a second total height at a bobbin side of a second base sheet so that an inner side of the one or more second spacer layers is at the bobbin side of the second base sheet wherein the second number of spacer layers is different than the first number of spacer layers, the second total height is different than the first total height, or both;
• driving a second needle thread through both the second base sheet and the one or more second spacer layers with the needle of the embroidery machine according to the programmed first pattern or a different programmed pattern that provides a second series of loops of the second needle thread that extends outward from the bobbin side of the second base sheet through the one or more second spacer layers and engages with a second bobbin thread disposed at an outer side of the one or more second spacer layers;
• bonding the second needle thread to a needle side of the second base sheet opposite from the bobbin side of the second base sheet;
• removing the second bobbin thread;
• and
• moving the one or more second spacer layers away from the second base sheet to slide the one or more second spacer layers off of the second series of loops, the second series of loops having a different height than the first series of loops.

A method of manufacturing an article, the method comprising:

• loading a soluble bobbin thread into an embroidery machine;
• disposing one or more first spacer layers at a bobbin side of a first base sheet so that an inner side of the one or more first spacer layers is at the bobbin side of the first base sheet;
• wherein there are a first number of first spacer layers that have a first total height;
• driving a first needle thread through both the first base sheet and the one or more first spacer layers with a needle of the embroidery machine according to a programmed first pattern that provides a first series of loops of the first needle thread extending through the first base sheet from a needle side of the first base sheet to the bobbin side of the first base sheet and into the one or first more spacer layers, and the soluble bobbin thread engaging the first series of loops outward of an outer side of the one or more first spacer layers;
• bonding the first needle thread to the needle side of the first base sheet opposite from the bobbin side of the first base sheet;
• applying a solvent to the soluble bobbin thread to dissolve the soluble bobbin thread;
• after applying the solvent to the soluble bobbin thread, moving the one or more first spacer layers away from the first base sheet to slide the one or more first spacer layers off of the first series of loops;
• disposing one or more second spacer layers that are a second number of spacer layers and have a second total height at a bobbin side of a second base sheet so that an inner side of the one or more second spacer layers is at the bobbin side of the second base sheet;
• wherein the second number of spacer layers is different than the first number of spacer layers, the second total height is different than the first total height, or both;
• driving a second needle thread through both the second base sheet and the one or more second spacer layers with the needle of the embroidery machine according to the programmed first pattern or a different programmed pattern that provides a second series of loops of the second needle thread that extends outward from the bobbin side of the second base sheet through the one or more second spacer layers and engages with a second bobbin thread disposed at an outer side of the one or more second spacer layers;
• bonding the second needle thread to a needle side of the second base sheet opposite from the bobbin side of the second base sheet;
• removing the second bobbin thread;
• and
• moving the one or more second spacer layers away from the second base sheet to slide the one or more second spacer layers off of the second series of loops, the second series of loops having a different height than the first series of loops.

A method of manufacturing an article, the method comprising:

• loading a soluble bobbin thread into an embroidery machine;
• 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 with the soluble bobbin thread engaging the series of loops outward of the bobbin side of the base sheet;
• bonding the needle thread to a needle side of the base sheet opposite from the bobbin side of the base sheet;
• applying a solvent to the soluble bobbin thread to dissolve the soluble bobbin thread;
• and
• prior to driving the needle thread through the base sheet, disposing a meltable bonding layer against the needle side of the base sheet;
• wherein driving the needle thread through the base sheet further comprises driving the needle thread through the meltable bonding layer;
• and
• wherein bonding the needle thread to the needle side of the base sheet includes applying heat to the meltable bonding layer.