CN107098192B

CN107098192B - Multi-frame manufacturing device for non-rigid material

Info

Publication number: CN107098192B
Application number: CN201710098763.8A
Authority: CN
Inventors: 托德·R·法尔; 安德烈·巴卡里奥夫; 吉拉德·达马里; 奥弗·里克利斯; 金在律
Original assignee: Nike Inc
Current assignee: Nike Inc
Priority date: 2016-02-23
Filing date: 2017-02-23
Publication date: 2020-07-07
Anticipated expiration: 2037-02-23
Also published as: MX2018010169A; US20170241058A1; TWM550227U; TW201919978A; CN207108019U; EP3419922B1; TW201730084A; TWI698388B; KR102144417B1; EP3419922A1; TWI730285B; WO2017147286A1; CN107098192A; KR20180115765A

Abstract

The invention relates to a multi-frame manufacturing device for non-rigid materials. Aspects herein relate to a multi-frame manufacturing apparatus for manufacturing an article from a non-rigid material and a method for manufacturing an article using the multi-frame manufacturing apparatus. The multi-frame manufacturing apparatus comprises a plurality of discrete frames, each frame comprising a movement mechanism enabling it to move between sequentially arranged processing stations. Each movement mechanism allows for substantially horizontal movement forward and backward. A movement mechanism for at least one of the frames allows for substantially vertical movement up and down. Actuation of the movement mechanism for the at least two frames may allow the frames to switch their relative positions. In addition, each frame includes at least one clamping mechanism for temporarily securing the non-rigid material in position on the frame for processing.

Description

Multi-frame manufacturing device for non-rigid material

Cross Reference to Related Applications

Not applicable.

Technical Field

Aspects herein relate to a multi-frame manufacturing apparatus for manufacturing an article. Aspects also relate to methods of manufacturing articles using the multi-frame manufacturing apparatus.

Background

The non-rigid material may be fed from a stock of material (including large rolls or continuous webs) into an assembly line or conveyor type manufacturing system or machine. Working with such large material parts can be cumbersome. This is true because non-rigid materials are typically stretchable in at least one direction when placed under tension. Attempting to process a non-rigid material in a tensioned state that causes the material to stretch can result in an article of manufacture that has errors or deformations and is therefore unusable.

Disclosure of Invention

Aspects herein relate to a multi-frame manufacturing apparatus for manufacturing articles (e.g., apparel, shoe linings, and the like) from non-rigid materials. The multi-frame manufacturing apparatus includes a plurality of discrete frames. Each frame includes a movement mechanism that moves the frame between sequentially arranged processing stations in an assembly line or conveyor type manufacturing system. Each movement mechanism allows for substantially horizontal movement forward and backward. In addition, the moving mechanism for at least one of the plurality of frames allows for substantially vertical movement up and down. The actuation, synchronization or asynchrony of the movement mechanisms for at least two of the plurality of frames may allow the frames to switch their relative positions in the processing stations in the manufacturing system.

Each frame includes at least one clamping mechanism including an open material receiving position and a closed material clamping position. When non-rigid material is loaded onto one of the frames, the clamping mechanism of the frame is in an open material receiving position. Once the material is in place and in a non-tensioned state (i.e., taut but not stretched such that the material is substantially undeformed in any direction), the clamping mechanism is closed to a closed material clamping position such that it temporarily secures the non-rigid material in place on the frame for processing. If the material is loaded from the stock material onto the frame by more than the amount required for processing as a single processing unit, the clamped portion of material may be cut or otherwise separated from the larger amount of material so that it may be processed more manageable.

Aspects herein also relate to methods of manufacturing articles using a multi-frame manufacturing apparatus included in a manufacturing system having a plurality of sequentially arranged processing stations in an assembly line or conveyor-type arrangement. The non-rigid material is loaded onto a first frame of the plurality of frames in a non-tensioned state. The first frame includes at least one clamping mechanism that is actuated once the material is in place on the first frame such that it closes and temporarily holds the non-rigid material in place on the frame for processing. The non-rigid material fixed to the first frame is under tension but not stretched so that no deformation of the material is caused. A movement mechanism coupled with the first frame causes the frame to move at least substantially horizontally in the first direction with the material in place. Synchronously or asynchronously, a second movement mechanism associated with the second frame is caused to move substantially vertically and substantially horizontally in the opposite direction to cause the first and second frames to switch their respective positions in the plurality of processing stations.

The present document also relates to the following aspects:

1) a manufacturing tool, comprising:

a first rectangular frame having at least one peripheral sidewall surrounding a first central void; and

a second rectangular frame having at least one peripheral sidewall surrounding a second central void,

wherein two opposing sides of each of the first and second rectangular frames include a clamping mechanism that temporarily clamps a non-rigid material and a movement mechanism that allows at least one of horizontal and vertical movement between first and second parallel side rails.

2) The manufacturing tool of 1), wherein the clamping mechanism is a clamping mechanism having an open material receiving position and a closed material clamping position.

3) The manufacturing tool of any of 1) to 2), wherein the non-rigid material comprises a tensile direction and a non-tensile direction, and wherein the clamping mechanism clamps the non-rigid material along the tensile direction.

4) The manufacturing tool of any of 1) to 3), wherein each of the first and second parallel side rails includes a first rail and a second rail, wherein the movement mechanism of the first rectangular frame is coupled with the first rail so as to allow horizontal movement, and wherein the movement mechanism of the second rectangular frame is coupled with the second rail so as to allow horizontal movement and vertical movement.

5) The manufacturing tool of 4), further comprising at least one linear actuator that causes the horizontal movement of the first and second rectangular frames.

6) The manufacturing tool of 5), further comprising at least one piston that causes the vertical movement of the second rectangular frame.

7) The manufacturing tool of 6), wherein the at least one linear actuator and the at least one piston cooperate with each other to allow the first and second rectangular frames to shift positions.

8) The manufacturing tool of any of 1) to 7), further comprising a material loading mechanism that loads the non-rigid material onto one of the first and second rectangular frames.

9) A manufacturing tool, comprising:

a first frame having a first pair of sidewalls positioned opposite each other and a second pair of sidewalls positioned opposite each other and perpendicular to the first pair of sidewalls to form a first rectangular structure;

a second frame having a first pair of sidewalls positioned opposite each other and a second pair of sidewalls positioned opposite each other and perpendicular to the first pair of sidewalls of the second frame to form a second rectangular structure; and

first and second parallel side rails spaced apart from each other by a distance sufficient to movably position the first and second frames between the first and second parallel side rails;

wherein the first frame and the second frame are movably positioned between the first parallel side rail and the second parallel side rail so as to allow for substantially horizontal movement forward and rearward,

wherein at least one of the first frame and the second frame is movably positioned between the first parallel side rail and the second parallel side rail so as to allow for substantially vertical movement upward and downward,

and wherein each of the first pair of sidewalls of the first frame and each of the first pair of sidewalls of the second frame comprise a clamping mechanism for temporarily clamping a non-rigid material.

10) The manufacturing tool of 9), wherein the clamping mechanism of each of the first pair of sidewalls of the first frame and the first pair of sidewalls of the second frame is a clamping mechanism having an open material receiving position and a closed material clamping position.

11) The manufacturing tool of any of claims 9) to 10), wherein the non-rigid material comprises a stretch direction and a non-stretch direction, and wherein the clamping mechanism clamps the non-rigid material along the stretch direction.

12) The manufacturing tool of any of claims 9) to 11), wherein each of the first and second parallel side rails includes a first rail and a second rail, and wherein each of the first pair of side walls of the first frame includes a first movement mechanism coupled with the first rail of each of the first and second parallel side rails so as to allow for horizontal movement, and wherein each of the first pair of side walls of the second frame includes a second movement mechanism coupled with the second rail of each of the first and second parallel side rails so as to allow for horizontal and vertical movement.

13) The manufacturing tool of any of claims 9) to 12), further comprising at least one linear actuator that moves the first frame and the second frame substantially horizontally.

14) The manufacturing tool of 13), further comprising at least one piston that moves at least one of the first frame and the second frame substantially vertically.

15) The manufacturing tool of 14), wherein the at least one linear actuator and the at least one piston cooperate with each other to allow the first frame and the second frame to shift positions.

16) The manufacturing tool of any of claims 9) to 15), further comprising a material loading mechanism that loads the non-rigid material onto one of the first frame and the second frame.

17) A method of manufacturing using a multi-frame manufacturing apparatus, comprising:

loading a non-rigid material onto a first rectangular frame at a loading station, the first rectangular frame having opposing sides each including a gripping mechanism and a first movement mechanism;

causing the clamping mechanism to temporarily clamp the non-rigid material to the first rectangular frame;

causing the first movement mechanism to move the first rectangular frame substantially horizontally in a first direction while simultaneously causing a second movement mechanism associated with a second rectangular frame to move substantially vertically and substantially horizontally in an opposite direction such that the second rectangular frame and the first rectangular frame exchange positions.

18) The method of 17), wherein the clamping mechanism is a clamping mechanism having an open material receiving position and a closed material clamping position.

19) The method of any of claims 17) to 18), wherein the non-rigid material comprises a stretch direction and a non-stretch direction, and wherein the clamping mechanism clamps the non-rigid material along the stretch direction.

20) The method of any of 17) to 19), wherein the first movement mechanism comprises at least one linear actuator that causes horizontal movement of the first rectangular frame, and wherein the second movement mechanism comprises at least one linear actuator that causes horizontal movement of the second rectangular frame and at least one piston that causes vertical movement of the second rectangular frame.

This summary is provided to introduce a selection of concepts in a simplified form that are further described below in the detailed description. This summary is not intended to identify key features or essential features of the claimed subject matter, nor is it intended to be used as an aid in determining the scope of the claimed subject matter.

Drawings

Illustrative aspects of the disclosure are described in detail below with reference to the attached drawing figures, which are incorporated herein by reference, and wherein:

FIG. 1 depicts an exemplary multi-frame manufacturing apparatus according to exemplary aspects herein;

FIG. 2 depicts a cross-sectional view of the multi-frame manufacturing apparatus of FIG. 1 taken along line 2-2 of FIG. 1, according to exemplary aspects herein;

FIG. 3 depicts a view of the area enclosed by line 3 in FIG. 1, in accordance with exemplary aspects hereof;

FIG. 4 depicts a view of an area enclosed by line 4 in FIG. 1, in accordance with exemplary aspects hereof;

FIG. 5 depicts a cross-sectional view of the second movement mechanism of FIG. 1 taken along line 5-5 of FIG. 1, according to an exemplary aspect hereof;

FIG. 6 depicts an exemplary multi-frame manufacturing apparatus having a loading mechanism engaged therewith, according to exemplary aspects herein;

fig. 7-11 are cross-sectional views depicting two frames sequentially moving and shifting positions according to a first frame shifting mechanism, according to an exemplary aspect hereof; and

fig. 12 depicts an exemplary multi-frame manufacturing apparatus having a second frame conversion mechanism according to further aspects herein.

Detailed Description

The subject matter herein is described with specificity to meet statutory requirements. However, the description itself is not intended to limit the scope of this patent. Rather, the inventors have contemplated that the claimed subject matter might also be embodied in other ways, to include different elements or combinations of elements similar to the combinations of elements described in this document, in conjunction with other present or future technologies.

Aspects herein contemplate a multi-frame manufacturing apparatus (e.g., a manufacturing apparatus having at least two discrete tooling frames) for manufacturing an article (e.g., a shoe insert) from a non-rigid material. The multi-frame manufacturing apparatus provides discrete portions in a non-tensioned state (i.e., tensioned but not stretched such that the material does not substantially deform in any direction) for manageable handling of large material stock of non-rigid material. For example, in an exemplary aspect, a multi-frame manufacturing apparatus temporarily secures discrete portions of a non-rigid material to a frame for processing. In aspects, the non-rigid material is secured to the frame along a stretch direction (i.e., along which the non-rigid material has the greatest relative direction of force to stretch or deform from its relaxed, taut, but unstretched state). In this way, waste caused by manufacturing deformed or otherwise misshapen articles is reduced since the non-rigid material is secured in a non-tensioned state during processing in order to prevent deformation thereof. Furthermore, handling discrete non-rigid material portions may be more manageable than processing continuously from large material stocks.

Aspects herein relate to a multi-frame manufacturing apparatus for manufacturing an article (e.g., a shoe insert, a garment, or a garment portion) from a non-rigid material. Non-rigid materials may include, by way of example and not limitation, knit (knit) materials, woven (woven) materials, mesh materials, nonwoven materials, leather materials, foam materials, and the like. By way of example only, non-rigid materials used to manufacture articles are typically supplied from a stock of material (e.g., a roll or web of material) having a large amount of material. Material from the material stock may be fed into the manufacturing system at a suitable processing station of a plurality of processing stations arranged in series in an assembly line. Non-rigid materials generally include a direction (referred to herein as the "stretch direction") along which the material has the greatest relative ability to stretch or deform from its relaxed, strained, but unstretched state when the material is in a tensioned or strained state (e.g., a stretched state). Such tensioning may cause the non-rigid material to deform during processing, resulting in a deformed or misshapen article of manufacture. Thus, in exemplary aspects, it may be desirable to maintain a non-rigid material in a non-tensioned state (i.e., taut but not stretched such that the material is substantially undeformed in any direction) during processing to reduce waste caused by the item or portion of the item that is deformed and thus unusable.

As will be discussed throughout, it is contemplated that a multi-frame manufacturing apparatus according to aspects herein may include at least two discrete frames configured to receive a non-rigid material and for moving the non-rigid material through a plurality of sequentially arranged processing stations positioned in a conveyor or assembly line type arrangement. In an exemplary aspect, the frame may be generally rectangular and movably positioned between a pair of side rails. As used herein, it is contemplated that "substantially rectangular" refers to a frame having a first pair of sidewalls positioned opposite each other and a second pair of sidewalls positioned opposite each other and perpendicular to the first pair of sidewalls. The side wall may be formed by one or more wall portions that collectively form a substantially rectangular peripheral side wall surrounding the central void. When multiple wall portions are assembled to form a generally rectangular peripheral sidewall, aspects herein contemplate that those wall portions that need to be attached to one another may have end portions that are cut at an angle of about forty-five degrees (45 °) to allow the wall portions to be mitered to form a rectangular structure. It should be understood that angles slightly deviating from 45 ° are contemplated and intended to fall within the scope of aspects herein. Further aspects herein contemplate connecting wall portions having abutting attachment surfaces at about ninety degrees (90 °) or any other angle that allows attachment relative to each other to form a rectangular structure. Any and all such variations, and any combination thereof, are contemplated as falling within the scope of the aspects herein. The means for securing the wall portion may include various screws or other securing mechanisms known to those of ordinary skill in the art.

Each frame may include a movement mechanism that allows substantially horizontal movement forward and backward between a pair of side rails. As used herein, the terms "forward" and "rearward" refer to reverse movement in the longitudinal direction of the side rail that is allowed to move therebetween. In various aspects, the pair of side rails may be positioned parallel to each other and spaced apart from each other a distance sufficient to allow for functionally receiving the frame. As used herein, "substantially horizontal movement" refers to horizontal movement in the longitudinal direction of the side rail, which may or may not include vertical movement to a lesser extent than horizontal movement. The generally horizontal movement results in a recognizable horizontal travel forward or backward, and may include, but is not necessarily required to include, a concurrent recognizable vertical travel. In addition, the moving mechanism for at least one of the two frames allows for substantially vertical movement up and down. As used herein, "upward" and "downward" refer to the reverse movement in the lateral direction of the side rail that is allowed to move therebetween. As used herein, "substantially vertical movement" refers to vertical movement in the lateral direction of the side rail, which may or may not include horizontal movement to a lesser extent than vertical movement. The generally vertical movement results in a recognizable vertical travel up or down, and may include, but is not necessarily required to include, a concurrent recognizable horizontal travel. In aspects, the movement mechanism for each of the two frames allows for substantially horizontal movement and substantially vertical movement.

Aspects herein contemplate that actuation of a movement mechanism for two frames of a multi-frame manufacturing apparatus may allow the two frames to shift positions relative to each other relative to a conveyor or assembly line processing station. The processing stations may include, for example, but not limited to, stations for cutting, pressing, molding, bonding, and the like. By way of example only, if a first of the two frames is at a first processing station and a second of the two frames is at a second processing station, the first and second processing stations being arranged sequentially with respect to one another, actuation of the movement mechanisms for the two frames may allow the first frame to advance to the second processing station (via substantially horizontal movement or via substantially horizontal movement and substantially vertical movement) and the second frame to advance to the first processing station (again, via substantially horizontal movement or via substantially vertical movement and substantially horizontal movement). As will be understood and appreciated by those of ordinary skill in the art, when two frames are stated herein as "transitioning positions," it is contemplated that the two frames do not necessarily transition to exactly the same position, but rather that the two frames exchange their relative positions during the manufacturing process. For example, if the first frame is in a processing station later in the sequence than the second frame during the manufacturing process, it is conceivable that the second frame is in a processing station later in the sequence than the first frame during the manufacturing process if both frames have the switched position after switching. In an exemplary aspect, the conversion of the frames relative to the processing stations of the manufacturing process allows for processing of material associated with one frame while the material is being loaded onto another frame. This increases manufacturing speed and efficiency because the process does not stop when new material is loaded into the processing system.

In various aspects, each frame may include one or more clamping mechanisms configured to temporarily secure a non-rigid material in a non-tensioned state (i.e., in a state in which the material is tensioned but not stretched) to the frame for processing such that the material is substantially undeformed in any direction. If the frame is a generally rectangular frame, aspects herein contemplate that the clamping mechanism is coupled (e.g., pivotally connected) with each of two opposing sidewalls of the generally rectangular frame. Each clamping mechanism may be configured as a clamping mechanism and may include an open material receiving position and a closed material clamping position. When non-rigid material is loaded onto the frame, the clamping mechanism of the frame may be in an open material receiving position. Once the material is in place and in a non-tensioned state, the clamping mechanism may be closed to a closed material clamping position such that it temporarily secures the non-rigid material in place on the frame for processing. In aspects, the clamping mechanism clamps the non-rigid material along a direction of tension (i.e., the direction along which the non-rigid material has the greatest relative force to stretch or deform from its relaxed, tensioned, but unstretched state). If the material is loaded from the stock material onto the frame by more than the amount required to be processed on the frame, the gripped portion of the material may be cut or otherwise separated from the larger amount of material so that it may be processed more manageable.

As will be discussed throughout, it is contemplated that aspects provided herein also relate to a method of manufacturing an article (or portion thereof) formed of a non-rigid material using a multi-frame manufacturing apparatus. The article may include, for example, but is not limited to, apparel, outerwear, shoe inserts, other portions of footwear, and the like. In an exemplary aspect, a quantity of non-rigid material is loaded from a stock of material onto a first frame using a material loading mechanism. The non-rigid material is loaded onto the first frame at a loading station, which is one of a plurality of sequentially arranged processing stations positioned in a conveyor or assembly line type arrangement. Aspects herein contemplate that the first frame may be generally rectangular and may be movably positioned between a pair of parallel side rails.

In aspects, the first frame may include one or more clamping mechanisms configured to temporarily secure a non-rigid material in a non-tensioned state (i.e., in a state in which the material is tensioned but not stretched) on the first frame for processing. When the first frame is generally rectangular, aspects herein contemplate that the clamping mechanism is coupled with each of two opposing side walls that are adjacent to the parallel side rails. Each gripper mechanism may be configured as a clamping mechanism and include an open material receiving position and a closed material gripping position. The clamping mechanism of the first frame may be in an open material receiving position when the non-rigid material is loaded onto the first frame at the loading station. Once the material is in its desired manufacturing position and in a non-tensioned state, the clamping mechanism may be closed to a closed material clamping position to temporarily secure the non-rigid material to the first frame for processing. In aspects, the non-rigid material is clamped along a direction of stretching (i.e., the direction having the greatest relative stretching or deformation capability). If the non-rigid material is loaded from the stock material onto the frame by more than the amount required for processing as a single processing unit, the clamped portion of material may be cut or otherwise separated from a larger amount of material.

The first frame may include at least one movement mechanism coupled thereto that allows for substantially horizontal movement forward and rearward between the pair of parallel side rails. In aspects, the parallel side rails are spaced apart from each other a distance sufficient to allow the first frame to move therebetween. In aspects, the movement mechanism may be actuated such that a first frame with material in place moves generally horizontally in a first direction, while synchronously or asynchronously, a second movement mechanism associated with a second frame is caused to move generally vertically and generally horizontally in a reverse direction such that the first frame and the second frame switch positions, the second frame also being generally rectangular and movably positioned between the pair of parallel side rails in accordance with aspects herein. In a further aspect, the movement mechanism may be actuated such that a first frame in which the material is in place moves substantially vertically and substantially horizontally in a first direction, while, synchronously or asynchronously, a second movement mechanism associated with a second substantially rectangular frame (which, according to aspects herein, is movably positioned between a pair of parallel side rails) is caused to move substantially vertically and substantially horizontally in a direction opposite the first direction such that the first frame and the second frame cooperate to switch their relative positions. One of ordinary skill in the art will understand and appreciate that when the first frame and the second frame exchange their relative positions during the manufacturing process, the first frame and the second frame have switched positions according to aspects herein.

In aspects, one or more of the moving mechanism for the first frame, the moving mechanism for the second frame, and the clamping mechanism may be manually actuated. In aspects, one or more of the moving mechanism and the clamping mechanism may be actuated by cooperating with a computing device (not shown) that is functionally and/or logically coupled to at least one of the multi-frame manufacturing apparatus, the processing station, and the frame. Any and all such variations, and any combination thereof, are contemplated as falling within the scope of the aspects herein.

Referring now to fig. 1, an exemplary multi-frame manufacturing apparatus 100 is depicted in accordance with aspects herein. The multi-frame manufacturing apparatus 100 includes a first frame 102, a second frame 104, and first and second parallel side rails 106, 108. It should be understood that additional elements may be included in alternative aspects. Further, it should be understood that in alternative exemplary aspects, one or more of the listed elements of the multi-frame manufacturing apparatus 100 may be omitted. Further, the multi-frame manufacturing apparatus 100 is depicted for illustrative purposes and may have alternative configurations, shapes, sizes, and arrangements.

Each of the first frame 102 and the second frame 104 are separate from each other, and as described more fully below, each of the first frame 102 and the second frame 104 are configured to temporarily secure a separate portion of the non-rigid material and move the portion of the non-rigid material through a plurality of sequentially arranged processing stations positioned in a conveyor or assembly line type arrangement. The first frame 102 includes a first pair of sidewalls 110, 112 positioned opposite each other and a second pair of

sidewalls

114, 116 positioned opposite each other and perpendicular to the first pair of sidewalls 110, 112 to form a generally rectangular structure. The

sidewalls

110, 112, 114, 116 may be formed from one or more wall portions that collectively form a generally rectangular peripheral sidewall surrounding the central void 118. The central void 118 provides a material processing area that is not disturbed by the first frame 102. In an exemplary aspect, the

sidewalls

110, 112, 114, 116 may each be discrete wall portions having end portions cut at an angle of about 45 ° in an arrangement that allows them to be mitered to form a generally rectangular perimeter sidewall configuration of the first frame 102. In an exemplary aspect, the

sidewalls

110, 112, 114, 116 may each be discrete wall portions having attachment surfaces that abut each other at approximately 90 ° or any other angle to allow attachment to each other to form a rectangular structure. Any and all such variations, and any combination thereof, are contemplated as falling within the scope of the aspects herein.

The means for securing the wall sections together may include various screws or other securing means known to those of ordinary skill in the art. It should be appreciated that the rectangular perimeter side walls collectively formed by the first and second pairs of

side walls

110, 112, 114, 116 may be formed as a continuous structure or may be formed by any number of wall portions. Further, any mechanism for securing the wall portions to one another may be used within the aspects herein. The formation of the first frame 102 and/or the mechanism for securing the wall portions that make up the first frame 102 is not intended to limit aspects herein in any way. Still further, it should be understood that frames having structures other than generally rectangular structures may be used in accordance with aspects herein. Any and all such variations, and any combination thereof, are contemplated as falling within the scope of the aspects herein.

Similar to the first frame 102, the second frame 104 includes a first pair of

sidewalls

120, 122 positioned opposite each other and a second pair of

sidewalls

124, 126 positioned opposite each other and perpendicular to the first pair of

sidewalls

120, 122 to form a generally rectangular structure. The

sidewalls

120, 122, 124, 126 may be formed from one or more wall portions that collectively form a generally rectangular peripheral sidewall surrounding a central void 128, the central void 128 providing a machining area that is not disturbed by the second frame 104. When multiple wall portions are assembled to form a generally rectangular peripheral sidewall, the wall portions may include attachment surfaces that abut each other at 45 °, 90 °, or any other desired angle to allow the wall portions to be connected to form a rectangular structure. The means for securing the wall sections together may include various screws or other securing means known to those of ordinary skill in the art. It is to be understood and appreciated that the rectangular perimeter side walls collectively formed by the first and second pairs of

side walls

120, 122, 124, 126 may be formed as a continuous structure or may be formed by any number of wall portions. Further, any mechanism for securing the wall portions to one another may be used within the aspects herein. The formation of the second frame 104 and/or the mechanisms for securing the wall portions that make up the second frame 104 is not intended to limit aspects herein in any way. Still further, it should be understood that frames having structures other than generally rectangular structures may be used in accordance with aspects herein. Any and all such variations, and any combination thereof, are contemplated as falling within the scope of the aspects herein.

Although the multi-frame manufacturing apparatus 100 of fig. 1 includes two

frames

102, 104, any number of frames is contemplated by aspects herein. For example, aspects herein are equally applicable to multi-frame manufacturing devices having three frames, four frames, five frames, and so forth. The number of frames comprising a multi-frame manufacturing apparatus as described throughout is not intended to limit the scope of aspects herein.

As previously described, each of the first frame 102 and the second frame 104 is configured for moving a quantity of non-rigid material through a plurality of sequentially arranged processing stations positioned in a conveyor or assembly line type arrangement. Thus, the first frame 102 includes a first movement mechanism 130 coupled thereto, and the second frame 104 includes a second movement mechanism 132 coupled thereto. Each of the first and

second movement mechanisms

130, 132 allows for generally horizontal movement between the pair of parallel side rails 106, 108, for example, forward and rearward in a longitudinal direction 168 (see fig. 6) of the pair of parallel side rails 106, 108. The second movement mechanism 132 also allows the second frame 104 to move generally vertically, e.g., upward and downward in a lateral direction 170 (see fig. 6) of the side rails 106, 108. As described more fully below, fig. 12 illustrates an aspect of the present disclosure in which both the first and second movement mechanisms allow for substantially horizontal movement and substantially vertical movement.

Turning now to fig. 2, a cross-sectional view of the multi-frame manufacturing apparatus 100 of fig. 1 is shown, the cross-sectional view being taken along line 2-2 of fig. 1. As shown, first parallel side rail 106 includes a first rail 134 and a second rail 136. The first rail 134 is positioned vertically below the second rail 136 in its lateral direction 170 (see fig. 6). One of ordinary skill in the art will appreciate that, although only shown with respect to the first side rail 106, the second side rail 108 includes a similar and opposite structure to the first and

second rails

134, 136 shown with respect to the first side rail 106.

A first movement mechanism 130 (visible with reference to fig. 1 and 3) is coupled to each of the first pair of opposing sidewalls 110, 112 of the first frame 102 and is configured to movably engage the first track 134. In various aspects, the first movement mechanism 130 can include a movement actuation device 131, such as a linear actuator, motor, or the like, that cooperates with the first track 134 to generally horizontally urge the first frame 102 in the forward and rearward directions. A second movement mechanism 132 (visible with reference to fig. 1, 2, and 4) is coupled to each of the first pair of opposing

sidewalls

120, 122 of the second frame 104 and is configured to movably engage with the second track 136. Referring to fig. 5, a cross-sectional view, taken along line 5-5 of fig. 1, is depicted showing the second movement mechanism 132 engaged with the second track 136 of the first parallel side rail 106. In various aspects, the second movement mechanism 132 may include a movement actuation device 133, such as a linear actuator, motor, or the like, that cooperates with the second track 136 to generally horizontally urge the second frame 104 in the forward and rearward directions. In exemplary aspects herein, the second movement mechanism 132 can further include at least one piston 135, the piston 135 cooperating with the second frame 104 to urge the second frame 104 generally vertically in an upward and downward direction. As described more fully below, the illustrated arrangement allows the second frame 104 to pass vertically over the first frame 102 when the two frames are moved in opposite horizontal directions, such that the relative positions of the first and

second frames

102, 104 with respect to the manufacturing apparatus 100 are switched when the first and

second movement mechanisms

130, 132 are actuated.

Referring back to fig. 2, a cross-sectional view of the multi-frame manufacturing apparatus 100 of fig. 1 taken along line 2-2 of fig. 1 is shown. First parallel side rail 106 includes a first rail 134 and a second rail 136, first rail 134 being positioned vertically below second rail 136. A first movement mechanism 130 (visible with reference to fig. 1 and 3) is coupled with the opposing side wall 110 of the first frame 102 and is configured to movably engage with the first track 134. The second movement mechanism 132 is coupled with the opposing side wall 120 of the second frame 104 and is configured to movably engage with the second track 136.

In various aspects, actuation of the first and

second movement mechanisms

130, 132 may cause the first and

second frames

102, 104 to shift positions relative to one another with respect to sequentially arranged processing stations. Exemplary processes by which this position transition may occur are shown with reference to fig. 7-10. Referring to fig. 7, the first frame is shown as having been moved substantially horizontally in a first direction, and the identifiable horizontal travel can be seen relative to the position of the first frame 102 in fig. 2. Referring to fig. 8, the second frame 104 is shown as having been moved generally vertically in an upward direction. Referring to fig. 9, once the second frame 104 is positioned over the first frame 102, the second frame 104 is caused to move generally horizontally in a horizontal direction opposite to the horizontal direction in which the first frame 102 is caused to move. As shown in fig. 10, synchronously, the first frame 102 is shown continuing its horizontal travel in the first direction. As shown in fig. 11. The second frame 104 is shown as having been moved substantially vertically in a downward direction such that the first frame 102 and the second frame 104 have switched their relative positions in the sequential arrangement of the processing stations.

Referring back to fig. 1, each of the first frame 102 and the second frame 104 includes one or more clamping mechanisms configured to temporarily secure a non-rigid material in a non-tensioned state in the

respective frame

102, 104 for processing. As shown, the first frame 102 includes a first clamping mechanism 138 and a second clamping mechanism 140 coupled to a first pair of opposing sidewalls 110, 112 thereof, which sidewalls 110, 112 are adjacent to the first and second parallel side rails 106, 108. Similarly, the second frame 104 includes a first clamping mechanism 142 and a second clamping mechanism 144 coupled to the first pair of opposing

sidewalls

120, 122 thereof. In various aspects, the clamping

mechanisms

138, 140, 142, 144 may be pivotally connected with the frame (as shown with reference to clamping mechanism 142 of fig. 5). Each of the first and second clamping mechanisms 138, 140 of the first frame 102 and the first and

second clamping mechanisms

142, 144 of the second frame 104 may be configured as a clamping mechanism (as shown) and include an open material receiving position and a closed material clamping position. The first and second clamping mechanisms 138, 140 of the first frame 102 are shown in an open material receiving position (as the second parallel side rail 108 substantially blocks the view of the second clamping mechanism 140, best seen at the first clamping mechanism 138). In the open material receiving position, the first and second clamping mechanisms 138, 140 are in a released state and do not substantially obscure the top surface of the first frame 102. In this manner, the first frame 102 may freely receive a non-rigid material over the central void 118 and around the peripheral sidewalls formed by the first and second pairs of

sidewalls

110, 112, 114, 116, as described more fully below. Additionally, the first clamping mechanism 138 of the first frame 102 in its open material receiving position is shown in the cross-sectional view of fig. 2 and in the view of fig. 3.

Once the desired material is in place on the desired frame and in a non-tensioned state (i.e., with the material taut but not stretched), the clamping mechanism may be closed or clamped to temporarily secure the non-rigid material in place and prevent deformities or other deformations. In fig. 1, the first clamping mechanism 142 and the second clamping mechanism 144 of the second frame 104 are shown in a closed material clamping position. In the closed material gripping position, the first and second

gripping mechanisms

142, 144 are in an actuated state and temporarily hold the non-rigid material above the central void 128 and to the top surfaces of the first pair of

side walls

120, 122 of the second frame 104 until the first and second

gripping mechanisms

142, 144 are released. Additionally, the first clamping mechanism 142 of the second frame 104 in its closed material clamping position is shown in the cross-sectional view of fig. 2 and in the view of fig. 4.

Exemplary aspects herein also relate to a method of manufacturing an article (or portion thereof) formed of a non-rigid material using a multi-frame manufacturing apparatus (e.g., a dual-frame manufacturing apparatus) arranged to move the non-rigid material through a plurality of sequentially arranged processing stations positioned in a conveyor or assembly line-type arrangement. Turning to fig. 6, fig. 6 is a perspective view depicting an exemplary multi-frame manufacturing apparatus 600 in cooperation with the material loading mechanism 146. The illustrated material loading mechanism 146 includes a roll 148 of non-rigid material and a loading frame 150, the loading frame 150 configured to facilitate loading of the non-rigid material to a first frame 152 at a material loading station 154 (e.g., a first station in a series of sequentially positioned processing stations in a conveyor or assembly line type arrangement). Non-rigid materials include a non-stretch direction 168 (i.e., a direction in which the material stretches or stretches relatively little when under tension) and a stretch direction 170 (i.e., a direction in which the material stretches or stretches relatively much when under tension). In an exemplary aspect, as shown, a portion of non-rigid material from the roll of material 148 may be loaded onto the first frame 152 at the material loading station 154 when the first and

second clamping mechanisms

156, 158 for the first frame 152 are in their open material receiving positions. Once the material has reached its desired placement relative to the first frame 152, the first 156 and second 158 clamping mechanisms for the first frame 152 may be closed to their closed material clamping positions to temporarily secure a portion of the non-rigid material to the first frame 152. The second frame 160 is shown in fig. 6, where a portion of the material 162 is secured to the second frame 160 by a closed first clamping mechanism 164 and a second clamping mechanism 166. In various aspects, once the material portion is secured to the frame, it may be cut or otherwise separated from the roll of material 148, and the loading frame 150 may be returned to a position disengaged from the frame.

As previously stated with reference to fig. 7-11, and as noted above, according to aspects herein, the movement mechanism associated with each of the first and

second frames

152, 160, respectively, may move the first frame 152 generally horizontally in a first direction, while the movement mechanism associated with the second frame may move the second frame 160 generally vertically and generally horizontally in an opposite direction such that the first and

second frames

152, 160 shift or exchange positions. In this manner, fabrication of one of the first frame 152 and the second frame 160 may continue while non-rigid material is being loaded onto the other of the first frame 152 and the second frame 160.

Referring now to fig. 12, an example multi-frame manufacturing apparatus 1200 is depicted having a first movement mechanism and a second movement mechanism that allow both substantially horizontal movement and substantially vertical movement, in accordance with aspects herein. As with the multi-frame manufacturing apparatus of fig. 1-11, multi-frame manufacturing apparatus 1200 includes a first frame 1202, a second frame 1204, and first and second

parallel side rails

1206 and 1208. It should be understood that additional elements may be included in alternative aspects. Further, it should be understood that in alternative exemplary aspects, one or more of the listed elements of the multi-frame manufacturing apparatus 1200 may be omitted. Further, the multi-frame manufacturing apparatus 1200 is depicted for illustrative purposes and may have alternative configurations, shapes, sizes, and arrangements.

Each of the first frame 1202 and the second frame 1204 are discrete from each other and are configured to temporarily secure a discrete portion of the non-rigid material and move the portion of the non-rigid material through a plurality of sequentially arranged processing stations positioned in a conveyor or assembly line type arrangement. The first frame 1202 includes a first pair of

side walls

1210, 1212 positioned opposite each other and a second pair of

side walls

1214, 1216 positioned opposite each other and perpendicular to the first pair of

side walls

1210, 1212 to form a generally rectangular structure. The

side walls

1210, 1212, 1214, and 1216 may be formed by one or more wall portions that collectively form a substantially rectangular peripheral side wall surrounding a central void (not shown). A central void (not shown) provides a material processing area that is not disturbed by the first frame 1202.

In an exemplary aspect, the

side walls

1210, 1212, 1214, 1216 may each be discrete wall portions having end portions cut at any other angle to allow attachment to each other to form a rectangular structure. The means for securing the wall sections together may include various screws or other securing means known to those of ordinary skill in the art. It should be understood that the rectangular perimeter side walls collectively formed by the first pair of

side walls

1210, 1212 and the second pair of

side walls

1214, 1216 may be formed as a continuous structure or may be formed by any number of wall portions. Further, any mechanism for securing the wall portions to one another may be used within the aspects herein. The formation of the first frame 1202 and/or the mechanisms for securing the wall portions making up the first frame 1202 is not intended to limit aspects herein in any way. Still further, it should be understood that frames having structures other than generally rectangular structures may be used in accordance with aspects herein. Any and all such variations, and any combination thereof, are contemplated as falling within the scope of the aspects herein.

Similar to the first frame 1202, the second frame 1204 includes a first pair of

sidewalls

1220, 1222 positioned opposite each other and a second pair of

sidewalls

1224, 1226 positioned opposite each other and perpendicular to the first pair of

sidewalls

1220, 1222 to form a generally rectangular structure. The

sidewalls

1220, 1222, 1224, 1226 may be formed by one or more wall portions that collectively form a generally rectangular peripheral sidewall surrounding a central void (not shown) that provides a machining area that is not disturbed by the second frame 1204. When multiple wall portions are assembled to form a generally rectangular peripheral side wall, the wall portions may include attachment surfaces that abut each other at any desired angle to allow the wall portions to be connected to form a rectangular structure. The means for securing the wall sections together may include various screws or other securing means known to those of ordinary skill in the art. It is to be understood and appreciated that the rectangular perimeter side walls collectively formed by the first pair of

side walls

1220, 1222 and the second pair of

side walls

1224, 1226 can be formed as a continuous structure or can be formed by any number of wall portions. Further, any mechanism for securing the wall portions to one another may be used within the aspects herein. The formation of second frame 1204 and/or the mechanism for securing the wall portions making up second frame 1204 is not intended to limit aspects herein in any way. Still further, it should be understood that frames having structures other than generally rectangular structures may be used in accordance with aspects herein. Any and all such variations, and any combination thereof, are contemplated as falling within the scope of the aspects herein.

Although the multi-frame manufacturing apparatus 1200 of fig. 12 includes two

frames

1202, 1204, any number of frames is contemplated by aspects herein. For example, aspects herein are equally applicable to multi-frame manufacturing devices having three frames, four frames, five frames, and so forth. The number of frames comprising the multi-frame manufacturing apparatus as described throughout is not intended to limit the scope of aspects herein.

As previously described, each of the first frame 1202 and the second frame 1204 are configured for moving a quantity of non-rigid material through a plurality of sequentially arranged processing stations positioned in a conveyor or assembly line type arrangement. Thus, the first frame 1202 includes a first movement mechanism 1230 coupled thereto, and the second frame 1204 includes a second movement mechanism 1232 coupled thereto. Each of the first and

second movement mechanisms

1230, 1232 allows for generally horizontal movement forward and rearward between the pair of

parallel side rails

1206, 1208, e.g., in the longitudinal direction 1268 of the pair of

parallel side rails

1206, 1208. Each of the first and

second movement mechanisms

1230, 1232 also allow the first and

second frames

1202, 1204 to move generally vertically upward and downward, respectively, e.g., in the lateral direction 1270 of the side rails 1206, 1208.

A first movement mechanism 1230 is coupled to each of the first pair of opposing

side walls

1210, 1212 and to the opposing

side rails

1206, 1208 of the first frame 1202 and is configured to movably engage the first side rail 1206 and the second side rail 1208. In various aspects, the first movement mechanism 1230 may include one or more movement actuation devices, e.g., linear actuators, motors, etc., that cooperate with the first and

second side rails

1206 and 1208 to urge the first frame 1202 generally horizontally in a forward and rearward direction and generally vertically in an upward and downward direction. A second movement mechanism 1232 is coupled to each of the first pair of opposing sidewalls 1220, 1222 of the second frame 1204 and to the opposing

side rails

1206, 1208, and is also configured to movably mate with the first and

second side rails

1206, 1208. In aspects, the second movement mechanism 1232 can include one or more movement actuation devices, e.g., linear actuators, motors, etc., that cooperate with the first and

second side rails

1206 and 1208 to urge the second frame 1204 generally horizontally in a forward and rearward direction and to urge the second frame 1204 generally vertically in an upward and downward direction. The illustrated arrangement allows the second frame 1204 to pass vertically over the first frame 1202 and/or the first frame 1202 to pass vertically over the second frame 1204 when the two frames are moved in opposite horizontal directions, such that when the first and

second movement mechanisms

1230, 1232 are actuated, the relative positions of the first and

second frames

1202, 1204 with respect to the manufacturing apparatus 1200 are switched.

In various aspects, actuation of the first and

second movement mechanisms

1230, 1232 can cause the first and

second frames

1202, 1204 to shift positions relative to each other with respect to sequentially arranged processing stations. Those of ordinary skill in the art will appreciate that the clamping mechanism described with respect to the aspects illustrated in fig. 1-11 is included in the multi-frame manufacturing apparatus 1200 of fig. 12 and functions as previously described.

As can be seen, aspects herein relate to a multi-frame manufacturing apparatus for manufacturing articles (e.g., shoe inserts) formed of non-rigid materials. Aspects herein also relate to a method of manufacturing an article (e.g., a shoe insert) using a multi-frame manufacturing apparatus. A multi-frame manufacturing apparatus having a structure as described herein allows the positions of multiple manufacturing frames to be interchangeable so that processing of one or more articles can be performed when loading material for another article onto the apparatus. The multi-frame manufacturing apparatus having the structure described herein also allows for processing a portion of non-rigid material separated from a larger material stock that remains in a non-tensioned state during processing and thus reduces waste caused by deformed and therefore unusable articles.

Although the multi-frame manufacturing apparatus and the method of manufacturing an article formed of a non-rigid material using the multi-frame manufacturing apparatus have been described above with reference to specific aspects, it should be understood that modifications and variations may be made without departing from the intended scope of protection provided by the following claims. It will be understood that certain features and subcombinations are of utility and may be employed without reference to other features and subcombinations. This is contemplated by and is within the scope of the claims.

Although specific elements and steps are discussed in conjunction with each other, it should be understood that any element and/or step provided herein is contemplated as being combinable with any other element and/or step, regardless of explicit provision of any other element and/or step, while still falling within the scope provided herein. Since many possible aspects may be made by the present disclosure without departing from the scope thereof, it is to be understood that all matter herein set forth or shown in the accompanying drawings is to be interpreted as illustrative and not in a limiting sense.

As used herein and in conjunction with the claims set forth below, the term "any one of the claims" or similar variants of said term are intended to be construed such that the features of the claims may be combined in any combination. For example, exemplary claim 4 may indicate the method/apparatus of any one of claims 1 to 3, which is intended to be construed such that the features of claim 1 and claim 4 may be combined, the elements of claim 2 and claim 4 may be combined, the elements of claim 3 and claim 4 may be combined, the elements of

claim

1, 2 and 4 may be combined, the elements of

claim

2, 3 and 4 may be combined, the elements of

claim

1, 2, 3 and 4 may be combined, and/or other variations. Furthermore, the term "any of the claims" or similar variations of said term are intended to include "any of the claims" or other variations of that term, as indicated by some of the examples provided above.

Claims

1. A manufacturing tool, comprising:

wherein two opposing sides of each of the first and second rectangular frames comprise a clamping mechanism that temporarily clamps a non-rigid material,

and wherein the first rectangular frame is movably positioned between the first parallel side rail and the second parallel side rail such that the first rectangular frame moves only substantially horizontally, wherein the second rectangular frame is movably positioned between the first parallel side rail and the second parallel side rail such that the second rectangular frame moves substantially horizontally and substantially vertically.

2. A manufacturing tool as claimed in claim 1, in which the clamping mechanism is a clamping mechanism having an open material receiving position and a closed material clamping position.

3. The manufacturing tool of claim 1, wherein the non-rigid material comprises a stretch direction and a non-stretch direction, and wherein the clamping mechanism clamps the non-rigid material along the stretch direction.

4. The manufacturing tool of claim 2, wherein the non-rigid material comprises a stretch direction and a non-stretch direction, and wherein the clamping mechanism clamps the non-rigid material along the stretch direction.

5. The manufacturing tool of any of claims 1-4, wherein each of the first and second parallel side rails includes a first rail and a second rail, wherein the movement mechanism of the first rectangular frame is coupled with the first rail so as to allow substantially horizontal movement, and wherein the movement mechanism of the second rectangular frame is coupled with the second rail so as to allow substantially horizontal movement and substantially vertical movement.

6. The manufacturing tool of claim 5, further comprising at least one linear actuator that causes the substantially horizontal movement of the first and second rectangular frames.

7. The manufacturing tool of claim 6, further comprising at least one piston that causes the substantially vertical movement of the second rectangular frame.

8. The manufacturing tool of claim 7, wherein the at least one linear actuator and the at least one piston cooperate with each other to allow the first and second rectangular frames to shift positions.

9. The manufacturing tool of any of claims 1 to 4 and 6 to 8, further comprising a material loading mechanism that loads the non-rigid material onto one of the first and second rectangular frames.

10. The manufacturing tool of claim 5, further comprising a material loading mechanism that loads the non-rigid material onto one of the first and second rectangular frames.

11. A manufacturing tool, comprising:

wherein the first frame is movably positioned between the first parallel side rail and the second parallel side rail such that the first frame moves only substantially horizontally, wherein the second frame is movably positioned between the first parallel side rail and the second parallel side rail such that the second frame moves substantially horizontally and substantially vertically,

12. The manufacturing tool of claim 11, wherein the clamping mechanism of each of the first pair of sidewalls of the first frame and the first pair of sidewalls of the second frame is a clamping mechanism having an open material receiving position and a closed material clamping position.

13. The manufacturing tool of claim 11, wherein the non-rigid material comprises a stretch direction and a non-stretch direction, and wherein the clamping mechanism clamps the non-rigid material along the stretch direction.

14. The manufacturing tool of claim 12, wherein the non-rigid material comprises a stretch direction and a non-stretch direction, and wherein the clamping mechanism clamps the non-rigid material along the stretch direction.

15. The manufacturing tool of any of claims 11 to 14, wherein each of the first and second parallel side rails includes a first rail and a second rail, wherein each of the first pair of side walls of the first frame includes a first movement mechanism coupled with the first rail of each of the first and second parallel side rails so as to allow substantially horizontal movement, and wherein each of the first pair of side walls of the second frame includes a second movement mechanism coupled with the second rail of each of the first and second parallel side rails so as to allow substantially horizontal and substantially vertical movement.

16. The manufacturing tool of any of claims 11 to 14, further comprising at least one linear actuator that moves the first frame and the second frame substantially horizontally.

17. The manufacturing tool of claim 15, further comprising at least one linear actuator that moves the first frame and the second frame substantially horizontally.

18. The manufacturing tool of claim 16, further comprising at least one piston that moves the second frame substantially vertically.

19. The manufacturing tool of claim 17, further comprising at least one piston that moves the second frame substantially vertically.

20. The manufacturing tool of claim 18, wherein the at least one linear actuator and the at least one piston cooperate with each other to allow the first frame and the second frame to shift positions.

21. The manufacturing tool of claim 19, wherein the at least one linear actuator and the at least one piston cooperate with each other to allow the first frame and the second frame to shift positions.

22. The manufacturing tool of any of claims 11 to 14 and 17 to 21, further comprising a material loading mechanism that loads the non-rigid material onto one of the first frame and the second frame.

23. The manufacturing tool of claim 15, further comprising a material loading mechanism that loads the non-rigid material onto one of the first frame and the second frame.

24. The manufacturing tool of claim 16, further comprising a material loading mechanism that loads the non-rigid material onto one of the first frame and the second frame.

25. A method of manufacturing using a multi-frame manufacturing apparatus, comprising:

loading a non-rigid material onto a first rectangular frame at a loading station, the first rectangular frame having opposing sides each including a gripper mechanism;

causing a first movement mechanism associated with the first rectangular frame to move the first rectangular frame substantially horizontally in only a first direction while simultaneously causing a second movement mechanism associated with a second rectangular frame to move substantially vertically and substantially horizontally in an opposite direction such that the second rectangular frame and the first rectangular frame exchange positions.

26. The method of claim 25, wherein the gripping mechanism is a clamping mechanism having an open material receiving position and a closed material gripping position.

27. The method of claim 25, wherein the non-rigid material comprises a stretch direction and a non-stretch direction, and wherein the gripping mechanism grips the non-rigid material along the stretch direction.

28. The method of claim 26, wherein the non-rigid material comprises a stretch direction and a non-stretch direction, and wherein the gripping mechanism grips the non-rigid material along the stretch direction.

29. The method of any one of claims 25 to 28, wherein the first movement mechanism comprises at least one linear actuator that causes substantially horizontal movement of the first rectangular frame, and wherein the second movement mechanism comprises at least one linear actuator that causes substantially horizontal movement of the second rectangular frame and at least one piston that causes substantially vertical movement of the second rectangular frame.