KR20180115765A - Non-rigid material multi-frame manufacturing equipment - Google Patents

Abstract

Embodiments of the present disclosure are directed to multi-frame manufacturing apparatuses for manufacturing articles from non-rigid materials and methods for manufacturing articles using multi-frame manufacturing apparatuses. The multi-frame manufacturing apparatus includes a plurality of separate frames (102, 104, 1202, 1204), each frame including a moving mechanism (130, 132, 1230) capable of moving a frame between sequentially disposed processing stations , 1232). Each of the moving mechanisms allows substantially horizontal movement forward and backward. The moving mechanism for at least one of the frames 102, 104, 1202, and 1204 allows substantially vertical movement both up and down. Operation of movement mechanisms for at least two frames 102, 104, 1202, 1204 may allow frames 102, 1202 to switch their relative positions. Each frame 102 additionally includes at least one gripping mechanism 142 for temporarily securing the non-rigid material 162 in place on the frame for machining.

Description

Non-rigid material multi-frame manufacturing equipment

Embodiments of the present disclosure are directed to a multiple frame manufacturing apparatus for manufacturing articles. The aspects also relate to methods of making articles using a multi-frame manufacturing apparatus.

Non-rigid materials may be supplied to the assembly line or conveyor type manufacturing system or machine from a material stock comprising a large roll or continuous web. Working with sections of this large material can be cumbersome. This is especially true when the non-rigid materials are generally stretchable in at least one direction when under tension. Attempts to process non-rigid materials in a stretched state that cause elongation of the material may lead to manufactured articles that have errors or deformations that are not available as a result.

Embodiments of the present disclosure are directed to a multiple frame manufacturing apparatus for manufacturing articles (e.g., garments, sockliners, etc.) from non-rigid materials. The multi-frame production apparatus includes a plurality of separate frames. Each frame includes a moving mechanism that can move the frame between the sequentially disposed processing stations in the assembly line-or conveyor-type manufacturing system. Each movement mechanism allows substantially horizontal movement both forward and rearward. The moving mechanism for at least one of the plurality of frames additionally allows for substantially vertical movement both up and down. The synchronous or asynchronous operation of the moving mechanisms for at least two of the plurality of frames can switch the relative positions of the frames among the processing stations in the manufacturing system.

Each frame includes at least one gripping mechanism including an open material receiving position and a closed material gripping position. When the non-rigid material is loaded into one of the frames, the gripping mechanism of the frame is in the open material receiving position. Once the material is in its untensioned condition (i. E., Stretched but not stretched so that the material is substantially not twisted in any direction), the gripping mechanism is closed to the closed material gripping position, The non-rigid material is temporarily fixed in place on the substrate. If the material is loaded on the frame and the material stock is larger than the amount desired for processing as a single processing unit, then the ripped portion of the material can be cut or otherwise separated from the larger amount of material, .

Embodiments of the present invention also relate to methods of manufacturing articles using multiple frame fabrication apparatus included in a fabrication system having a plurality of sequentially arranged processing stations in an assembly line-or conveyor-type arrangement. The non-rigid material is loaded in a non-stretched state on the first of the plurality of frames. The first frame includes at least one gripping mechanism that is actuated to temporarily hold the non-rigid material in place on the frame for processing, once the material is in place on the first frame. The non-rigid material fastened to the first frame is in a taut condition, but is not stretched, causing twisting of the material. The movement mechanism associated with the first frame allows the frame to move at least substantially horizontally in the first direction with the material in place. Synchronously or asynchronously, the second moving mechanism associated with the second frame is moved substantially horizontally in the opposite direction and the first frame and the second frame are moved substantially vertically to switch the respective positions between the plurality of processing stations do.

This summary is provided to introduce a simple form of concept selection, which is further described below in the detailed description. This summary is not intended to identify key features or essential features of the claimed subject matter and is not intended to be used as an aid in determining the scope of the claimed subject matter.

Exemplary aspects of the disclosure are described in detail below with reference to the accompanying drawings, which are incorporated herein by reference.

Figure 1 illustrates an exemplary multi-frame manufacturing apparatus according to exemplary aspects of the present disclosure.
2 illustrates a cross-sectional view of the multi-frame manufacturing apparatus of FIG. 1 taken along line 2--2 of FIG. 1 in accordance with exemplary aspects of the present disclosure.
FIG. 3 shows a view of a region surrounded by line 3 of FIG. 1 in accordance with exemplary aspects of the present disclosure.
4 shows a view of a region surrounded by line 4 of Fig. 1 according to exemplary aspects of the present disclosure.
Figure 5 shows a cross-sectional view of the second moving mechanism of Figure 1 taken along line 5--5 of Figure 1 in accordance with exemplary aspects of the present disclosure.
Figure 6 illustrates an exemplary multi-frame manufacturing apparatus having a cooperating loading mechanism in accordance with exemplary aspects of the present disclosure.
Figures 7-11 are cross-sectional views illustrating sequential movement and placement of two frames according to a first frame switching mechanism, in accordance with exemplary aspects of the present disclosure.
12 illustrates an exemplary multi-frame manufacturing apparatus having a second frame switching mechanism, in accordance with additional aspects of the present disclosure.

The subject matter is specifically addressed 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 may also be practiced otherwise than with other patents or future techniques, including combinations of elements similar or similar to those described in this document.

Aspects of the present disclosure contemplate a multi-frame manufacturing apparatus (e.g., a manufacturing apparatus having at least two separate processing frames) for manufacturing articles from non-rigid materials, for example, sockliners. The multi-frame manufacturing apparatus provides for easy handling of discrete portions of large material stocks of non-rigid material in the untensioned state (i.e., tightened but not stretched, so that the material does not substantially twist in any direction). For example, in exemplary aspects, a multiple frame manufacturing apparatus temporarily secures separate portions of non-rigid material to frames for processing. In aspects, the non-rigid material is secured to the frames along the stretching direction (i.e., the direction in which the non-rigid material is relaxed and has the greatest relative ability to stretch or deform from a stretched but unstretched state). In this way, the non-rigid material is deformed as the non-rigid material is fixed in the untensioned state during processing to prevent such deformation, or the waste caused by the manufacture of otherwise misshapen articles is reduced. Further, the separated non-rigid material portions may be handled more manageably than continuously machining from a large material stock.

Embodiments of the present disclosure are directed to a multi-frame manufacturing apparatus for making articles from non-rigid materials, such as sockliners, garments, or garment portions. Non-rigid materials may include, by way of example and not limitation, knitted materials, weaving materials, mesh materials, nonwoven materials, leather materials, foam materials, and the like. Non-rigid materials used in the manufacture of articles are often supplied from material stocks (e.g., material rolls or webs) having a large amount of material, by way of example only. The material from the material stock may be supplied to the manufacturing system at a suitable one of a plurality of processing stations sequentially disposed in the assembly line. Non-rigid materials generally have a largest relative ability to stretch or deform from a relaxed, tight but unstretched state when the material is in a stretched or strained state (e.g., in an elongated state) Quot; stretching direction "). Such tensile may result in deformation of the non-rigid material during processing, resulting in deformed or malformed manufactured articles. As such, in exemplary embodiments, maintaining the placement of non-rigid materials in a non-tensioned state during processing (i.e., not strained but not stretched, so that the material does not substantially twist in any direction) It may be desirable to reduce the waste caused by the manufacture of parts or parts of the articles which are not capable of being produced.

As discussed generally, multi-frame manufacturing apparatus according to aspects of the present disclosure may include a non-rigid material through a plurality of sequentially disposed processing stations positioned in a conveyor- or assembly line- It is contemplated that the at least two separate frames may be configured to move. In the exemplary embodiments, the frames may be positioned to be movable between substantially rectangular and paired side rails. As used herein, "substantially rectangular" refers to frames having a first pair of sidewalls positioned oppositely to each other, and a second pair of sidewalls positioned opposite to each other and perpendicular to the first pair of sidewalls . The sidewalls may be formed from one or more wall portions that collectively form a substantially rectangular peripheral sidewall surrounding the central void. When assembling a plurality of wall portions to form a substantially rectangular peripheral wall, aspects of the present invention include that such wall portions requiring attachment to one another have distal portions cut at angles of about 45 degrees such that the wall portions are mitered to allow for the formation of a rectangular structure. It will be understood that angles slightly deviating from 45 [deg.] Are contemplated and are intended to be within the scope of the present disclosure. Additional aspects of the present disclosure contemplate a combination of wall portions having adjacent attachment surfaces at about 90 [deg.] Relative to each other or at any other angle permitting attachment to form a rectangular structure. Any and all such modifications and any combination thereof are contemplated as being within the scope of the present aspects. The mechanisms for fastening the wall portions may include various screws or other fastening mechanisms known to those skilled in the art.

Each frame may include a movement mechanism that allows substantially horizontal movement between the paired side rails both forward and rearward. As used herein, the terms "front" and "rear" refer to longitudinally opposed motions of side rails that are allowed to move. In embodiments, the paired side rails may be positioned parallel to each other and spaced apart from each other by a distance sufficient to allow for functional accommodation of the frames. As used herein, "substantially horizontal motion" also refers to longitudinal motion of the side rails in the longitudinal direction, which may or may not include vertical motion to a lesser extent than horizontal motion. Substantially horizontal motion induces a horizontal progression that is identifiable forward or backward, and may, but need not, include simultaneous identifiable vertical progression. The movement mechanism for at least one of the two frames additionally allows for substantially vertical movement both up and down. As used herein, "upper" and "downward" refer to motions opposing in the latitudinal direction of the side rails to which motion is permitted. As used herein, "substantially vertical motion" also refers to vertical motion in the latitudinal direction of the side rails, which may or may not include horizontal motion to a lesser degree than vertical motion. Substantially vertical motion induces vertical progression that is identifiable as either upward or downward, and may, but need not, include simultaneous identifiable horizontal progression. In aspects, the moving mechanism for each of the two frames allows both a substantially horizontal motion and a substantially vertical motion.

Aspects of the present application, it is contemplated that the actuation of movement mechanisms for two frames of a multi-frame production apparatus may allow the two frames to switch positions relative to the conveyor- or assembly line processing stations. The processing stations may include, by way of example and not limitation, stations for cutting, pressing, molding, gluing, and the like. By way of example only, if the first of the two frames is at the first processing station and the second of the two frames is at the second processing station and the first and second processing stations are arranged sequentially with respect to each other, The actuation of the moving mechanisms for the frames allows the first frame to proceed to the second processing station (through substantially horizontal motion or substantially horizontal and substantially vertical motion) and the second frame Movement or substantially vertical and substantially horizontal movement) to the first processing station. As will be understood and appreciated by those skilled in the art, when two frames are specified herein as "switching positions ", the two frames do not necessarily have to be switched to exactly the same positions, It is considered to change their relative positions. For example, if the first frame is at a later processing station in the manufacturing process sequentially than the second frame, then after switching, if the second frame is at a later processing station in the manufacturing process than in the first frame, It is considered to have switched positions. In exemplary embodiments, switching of frames to the processing stations of the manufacturing process while the material is being loaded into another frame allows processing of the material associated with one frame. This increases production speed and efficiency because the processing is not interrupted when the new material is loaded into the processing system.

In aspects, each frame is configured to temporarily hold the non-rigid material on the frame in a non-stretched state for processing, i.e., the material is stretched but not stretched, so that the material is not substantially twisted in any direction And may include one or more gripping mechanisms configured. If the frame is a substantially rectangular frame, aspects of the present invention contemplate gripping mechanisms associated (e.g., pivotally pivotally connected) with each of the two opposing side walls. Each gripping mechanism may be configured as a clamping mechanism and may include an open material receiving position and a closed material gripping position. When the non-rigid material is loaded onto the frame, the gripping mechanisms of the frame may be in an open material receiving position. Once the material is in its untensioned position, the gripping mechanisms can be closed to the closed material gripping position so that the tools temporarily hold the non-rigid material in place on the frame for machining. In aspects, the gripping mechanisms grip the non-rigid material along the stretching direction (i.e., the direction in which the non-rigid material is relaxed and has the greatest relative ability to elongate or deform from a tensioned but unstretched state) . If the material stock into which the material is loaded into the frame is greater than the amount desired for processing in 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 more easily manipulated.

As discussed throughout, aspects provided herein are also contemplated with respect to a method of manufacturing articles (or portions thereof) formed from non-rigid materials using a multi-frame manufacturing apparatus. The articles may include, by way of example and not limitation, garments, outerwear, sockliners, other parts of the shoes, and the like. In exemplary embodiments, a large amount of non-rigid material is loaded onto the first frame from the material stock using a material loading mechanism. The non-rigid material is loaded into the first frame at a loading station, which is one of a plurality of sequentially disposed processing stations positioned in a conveyor- or assembly line-type arrangement. Aspects of the present application contemplate that the first frame may be substantially rectangular and may be movably positioned between the paired parallel side rails.

In aspects, the first frame may include one or more gripping mechanisms configured to temporarily secure the non-rigid material to the first frame in a non-tensioning condition for processing (i.e., the material is strained but not stretched) have. When the first frame is substantially rectangular, aspects of the present invention contemplate gripping mechanisms associated with each of the two opposing side walls, with the two opposite side walls being adjacent to the parallel side rails. Each gripping mechanism may be configured as a clamping mechanism and may include an open material receiving position and a closed material gripping position. When the non-rigid material is loaded on the first frame at the loading station, the gripping mechanisms of the first frame may be in the open material receiving position. Once the material is in the untensioned state at its desired manufacturing location, the gripping mechanisms may be closed to the closed material gripping position to temporarily secure the non-rigid material to the first frame for processing. In aspects, the non-rigid material is ripped along the stretching direction (i.e., the direction having the greatest relative ability to stretch or deform). If the material stock on which the non-rigid material is loaded on the frame is greater than the amount desired for processing as a single machining unit, then the gripped portion of the material may be cut or otherwise separated from the larger amount of material.

The first frame may include at least one moving mechanism coupled with the frame to allow substantially horizontal movement both front and rear between the paired parallel side rails. In aspects, the parallel side rails are spaced apart from each other by a distance sufficient to allow movement of the first frame therebetween. In aspects, the moving mechanism is actuated to move the first frame substantially horizontally while keeping the material in place, synchronously or asynchronously, and in a substantially rectangular, parallel, paired manner in accordance with the aspects herein The second moving mechanism associated with the second frame, which is movably positioned between the side rails, is moved substantially horizontally and substantially vertically in the opposite direction to allow the first frame and the second frame to switch positions. In additional aspects, the moving mechanism may be actuated to move the first frame substantially horizontally and substantially vertically in a first direction while keeping the material in place, synchronously or asynchronously (with the pairs in accordance with aspects herein) The second moving mechanism associated with the second substantially rectangular frame (which is movably positioned between the parallel side rails constituting the first frame) is moved substantially horizontally and substantially vertically in the direction opposite to the first direction, And the second frame cooperate to switch positions. It will be understood and appreciated by those skilled in the art that the first frame and the second frame switch positions in accordance with aspects of the present invention when the first and second frames change their relative positions in the manufacturing process.

In aspects, one or more of the moving mechanism for the first frame, the moving mechanism for the second frame, and the gripping mechanisms may be manually operated. In aspects, one or more of the moving mechanisms and gripping mechanisms may be adjusted (e.g., by manipulation) to a computing device (not shown) that is functionally and / or logically coupled to the at least one of the multiple frame manufacturing apparatuses, It may be activated. Any and all such modifications and any combination thereof are contemplated as being within the scope of the present aspects.

Referring now to FIG. 1, there is shown an exemplary multi-frame manufacturing apparatus 100 according to aspects of the present disclosure. The multi-frame manufacturing apparatus 100 includes a first frame 102, a second frame 104, and first and second parallel side rails 106 and 108. It is understood that additional elements may be included in alternative embodiments. It is also understood that one or more of the listed elements of the multi-frame fabrication apparatus 100 may be omitted in alternative exemplary aspects. In addition, the multi-frame manufacturing apparatus 100 is shown for exemplary purposes and may have alternative configurations, molding, sizing, and arrangement.

Each of the first and second frames 102,104 is separate from one another and can be used to temporarily hold separate portions of the non-rigid material and to place the conveyor- or assembly line-type arrangement And configured to move a portion of the non-rigid material through a plurality of positioned sequentially disposed processing stations. The first frame 102 includes a first pair of sidewalls 110 and 112 positioned opposite to each other and a second pair of sidewalls facing each other and vertically positioned in the first pair of sidewalls 110 and 112 114, and 116 to form a substantially rectangular structure. The sidewalls 110, 112, 114, 116 may be formed from one or more wall portions collectively forming a substantially rectangular peripheral sidewall surrounding the central void 118. The center void 118 provides a material processing area free of interference by the first frame 102. In the exemplary embodiments, the sidewalls 110, 112, 114, and 116 are each about 45 in the arrangement allowing the wall portions to be mitered to form a substantially rectangular peripheral sidewall structure of the first frame 102 RTI ID = 0.0 > angles. ≪ / RTI > In the exemplary embodiments, the sidewalls 110, 112, 114, 116 each have a separate wall portion 110 having attachment surfaces that are adjacent to each other at any other angle that allows attachment to each other to form a substantially 90 [ . Any and all such modifications and any combination thereof are contemplated as being within the scope of the present aspects.

Mechanisms for fastening the wall portions together may include a variety of screws or other fastening mechanisms known to those skilled in the art. It will be appreciated that the rectangular peripheral sidewalls collectively formed from the first and second pairs of sidewalls 110, 112, 114, 116 may be formed as a continuous structure or from any number of wall portions. In addition, any mechanism for fastening the wall portions to one another may be utilized within the context of the present disclosure. The mechanism for forming the first frame 102 and / or securing the wall portions including the first frame 102 is not intended to limit the embodiments in any way. Still further, it is understood that frames having substantially rectangular and other structures may be utilized in accordance with aspects of the present disclosure. Any and all such modifications and any combination thereof are contemplated as being within the scope of the present aspects.

Similar to the first frame 102, the second frame 104 includes a first pair of sidewalls 120, 122 positioned opposite to each other and a second pair of sidewalls 120, To define a substantially rectangular structure including a second pair of sidewalls 124, 126 positioned with respect to each other. The sidewalls 120, 122, 124, and 126 may include one or more walls < RTI ID = 0.0 > Or < / RTI > When the plurality of wall portions are assembled to form a substantially rectangular peripheral sidewall, the wall portions may be arranged at an angle of 45 [deg.], 90 [deg.], Or any other desired angle, . Mechanisms for fastening the wall portions together may include a variety of screws or other fastening mechanisms known to those skilled in the art. It will be understood and appreciated that the rectangular peripheral sidewalls collectively formed from the first and second pairs of sidewalls 120, 122, 124, 126 may be formed as a continuous structure or from any number of wall portions. In addition, any mechanism for fastening the wall portions to one another may be utilized within the context of the present disclosure. The mechanism for forming the second frame 104 and / or securing the wall portions including the second frame 104 is not intended to limit the aspects of the present disclosure in any way. Still further, it is understood that frames having substantially rectangular and other structures may be utilized in accordance with aspects of the present disclosure. Any and all such modifications and any combination thereof are contemplated as being within the scope of the present aspects.

Although the multi-frame production apparatus 100 of FIG. 1 includes two frames 102 and 104, aspects of the present disclosure consider any number of frames. For example, aspects of the present invention are equally applicable to a multi-frame manufacturing apparatus having three frames, four frames, five frames, and the like. The number of frames including multi-frame fabrication apparatus as generally described is not intended to limit the scope of aspects of the present disclosure.

As described above, the first frame 102 and the second frame 104 each move a large amount of non-rigid material through a plurality of sequentially disposed processing stations positioned in a conveyor- or assembly line-type arrangement . As such, the first frame 102 includes a first moving mechanism 130 coupled thereto, and the second frame 104 includes a second moving mechanism 132 coupled thereto. Each of the first moving mechanism 130 and the second moving mechanism 132 is configured to be movable between a pair of parallel side rails 106,108 in a forward and aft direction both in the longitudinal direction 168 (see Figure 6) Allows exercise. The second moving mechanism 132 also permits substantially vertical movement of the second frame 104 both in the upper and lower directions, e.g., in the latitudinal direction 170 (see FIG. 6) of the side rails 106, 108. As described more fully below, Figure 12 shows an embodiment in which both the first moving mechanism and the second moving mechanism allow substantially horizontal and substantially vertical movement.

Returning to Fig. 2, a cross-sectional view of the multi-frame manufacturing apparatus 100 of Fig. 1 is shown, and a cross-sectional view is taken along line 2--2 of Fig. As shown, the first parallel side rail 106 includes a first track 134 and a second track 136. The first track 134 is positioned vertically below the second track 136 in the latitudinal direction 170 (see FIG. 6). The second side rails 108 are disposed on the first track 134 and the second track 136 that are similar to the first track 134 and the second track 136 shown in association with the first side rail 106, Structure as will be understood by those skilled in the art.

The first moving mechanism 130 (see FIGS. 1 and 3) is coupled to each of the opposing side walls 110, 112 of the first pair of first frames 102, As shown in FIG. The first movement mechanism 130 includes a motion actuating device 131 that cooperates with the first track 134 to propel the first frame 102 substantially horizontally in the anteroposterior direction such as a linear actuator, A motor, and the like. The second moving mechanism 132 (see FIGS. 1, 2 and 4) is engaged with each of the opposing side walls 120, 122 of the first pair of second frames 104, RTI ID = 0.0 > 136 < / RTI > 5, there is shown a cross-sectional view showing a second moving mechanism 132 cooperating with a second track 136 of a first parallel side rail 106, . The second moving mechanism 132 includes a motion actuating device 133 that cooperates with the second track 136 to propel the second frame 104 substantially horizontally in the anteroposterior direction such as a linear actuator, A motor, and the like. The second moving mechanism 132 also includes at least one piston 135 cooperating with the second frame 104 to propel the second frame 104 substantially vertically up and down ). As described more fully below, when two frames are moved in opposite horizontal directions so that the relative position relative to the manufacturing apparatus 100 is switched when the first moving mechanism 130 and the second moving mechanism 132 are operated The illustrated arrangement allows the second frame 104 to vertically pass over the first frame 102. [

Referring again to FIG. 2, there is shown a cross-sectional view of the multi-frame manufacturing apparatus 100 of FIG. 1 taken along line 2--2 of FIG. The first parallel side rail 106 includes a first track 134 and a second track 136 and the first track 134 is positioned vertically below the second track 136. [ The first moving mechanism 130 (see FIGS. 1 and 3) is coupled with the opposing side wall 110 of the first frame 102 and is configured to move cooperatively with the first track 134 . The second moving mechanism 132 is configured to engage with the opposing side wall 120 of the second frame 104 and moveably cooperate with the second track 136.

The operation of the first moving mechanism 130 and the second moving mechanism 132 is such that the first frame 102 and the second frame 104 are moved to position one another . An exemplary process in which such a position change may occur is illustrated with reference to FIGS. Referring to Fig. 7, the first frame is shown to be moved substantially horizontally in a first direction, and in Fig. 2 an identifiable horizontal progression to the position of the first frame 102 can be seen. Referring to Fig. 8, the second frame 104 is shown to be moved substantially vertically in an upward direction. 9, when positioned to pass through the first frame 102, the second frame 104 is moved substantially horizontally in the horizontal direction opposite to the horizontal direction in which the first frame 102 is moved . As shown in FIG. 10, synchronously, the first frame 102 is shown as continuing horizontal progression in the first direction. As shown in FIG. 11, the first and second frames 102 and 104 are shown as being moved substantially vertically downward to switch the relative arrangement in a sequential arrangement of processing stations .

Referring again to Figure 1, each of the first frame 102 and the second frame 104 is configured to temporarily hold a non-rigid material in each frame 102, 104 in a non- Lt; / RTI > As shown, the first frame 102 includes a plurality of side walls 110, 112 adjacent its first pair of side walls 110, 112, first and second parallel side rails 106, And first and second gripping mechanisms 138 and 140 coupled with the first and second gripping mechanisms 138 and 140, respectively. Similarly, the second frame 104 includes first and second gripping mechanisms 142, 144 coupled with its opposing first pair of side walls 120, 122. In aspects, gripping mechanisms 138, 140, 142 and 144 may be pivotally connected to the frame (as shown for gripping mechanism 142 in FIG. 5). Each of the first and second gripping mechanisms 138 and 140 of the first frame 102 and the first and second gripping mechanisms 142 and 144 of the second frame 104 are positioned May be configured as a clamping mechanism and may include an open material receiving position and a closed material gripping position. The first and second gripping mechanisms 138 and 140 of the first frame 102 are positioned in an open material receiving position wherein the second parallel side rail 108 is shown in the drawing of the second gripping mechanism 140 Which is best seen in the first gripping mechanism 138. In the open material receiving position, the first and second gripping mechanisms 138, 140 are in the released state, The first frame 102 includes a first pair of sidewalls 110 and 112 and a second pair of sidewalls 114 as described more fully below, 116. The first gripping mechanism 138 of the first frame 102 at the open material receiving position may be configured to receive additional As well as the cross-sectional view of Fig.

Once the desired material is in place in the untensioned state (i.e., the material is in a tightened but unstretched state) on the desired frame, the gripping mechanisms are temporarily closed to lock the non-rigid material in place and prevent malformation or other deformation It may be clamped. In Figure 1, the first and second gripping mechanisms 142, 144 of the second frame 104 are shown in the closed material gripping position. In this closed material gripping position, the first and second gripping mechanisms 142, 144 are in the operative state and by this time the first and second gripping mechanisms 142, 144 are released, Stiff material through the center void 128 on the top surface of the first pair of sidewalls 120, 122 of the first layer 104. The first gripping mechanism 142 of the second frame 104 at the closed material gripping position is additionally shown in the view of FIG. 4 as well as the cross-sectional view of FIG.

Exemplary aspects of the present disclosure also relate to a multi-frame manufacturing apparatus (e.g., a two-dimensional work station) arranged to move non-rigid materials through a plurality of sequentially disposed processing stations positioned in a conveyor- or assembly line- (Or parts thereof) from non-rigid materials by using a frame manufacturing apparatus. Returning to Fig. 6, there is shown a perspective view of an exemplary multi-frame manufacturing apparatus 600 cooperating with a material loading mechanism 146. As shown in Fig. The depicted material loading mechanism 146 may be used in a series of sequentially positioned processing stations in a roll 148 of a non-rigid material and a material loading station 154 (e.g., a conveyor- or assembly line- (Not shown) to the first frame 152 to allow loading of the non-rigid material. The non-rigid material may be oriented in a non-stretching direction 168 (i.e., a direction of relatively less stretch or elasticity when the material is in tension) and a stretching direction 170 (i.e., Direction of greater elongation or elasticity). In the exemplary embodiments, as shown, when the first and second gripping mechanisms 156, 158 for the first frame 152 are in their open material receiving positions, A portion of the rigid material may be loaded into the first frame 152 at the material loading station 154. Once the material has reached the desired placement for the first frame 152, the first and second gripping mechanisms 156, 158 for the first frame 152 are closed to their closed material gripping position So that a portion of the non-rigid material can be temporarily fixed to the first frame 152. The second frame 160 is shown in Fig. 6 with a portion of the material 162 secured by closed first and second gripping mechanisms 164,166. In aspects, once a portion of the material is fixed to the frame, it may be cut or otherwise separated from the material roll 148 and the loading frame 150 may be returned to the frame and the disengaged position.

According to aspects of the present disclosure, each of the movement mechanisms associated with each of the first frame 152 and the second frame 160, as described above with reference to Figures 7 to 11, includes a first frame 152, And the moving mechanism associated with the second frame synchronously moves the second frame 160 substantially horizontally and substantially vertically in the opposite direction to move the first frame 152 and the second frame 160 in the opposite direction, 2 frame 160 switches or changes positions. In this way, the manufacturing for one of the first and second frames 152, 160 will continue while the non-rigid material is being loaded into the other of the first and second frames 152, 160.

Referring now to FIG. 12, an exemplary multi-frame manufacturing apparatus 1200 having first and second moving mechanisms that permit both substantially horizontal motion and substantially vertical motion is depicted in accordance with aspects of the present disclosure. 1 to 11, the multiple frame manufacturing apparatus 1200 includes a first frame 1202, a second frame 1204 and first and second parallel side rails 1206 and 1208 . It is understood that additional elements may be included in alternative embodiments. It is also understood that one or more of the listed elements of the multi-frame fabrication apparatus 1200 may be omitted in alternative exemplary aspects. In addition, the multi-frame production apparatus 1200 is shown for illustrative purposes and may have alternative configurations, formations, sizes, and arrangements.

Each of the first and second frames 1202 and 1204 is separated from one another and is configured to temporarily hold separate portions of the non-rigid material and to position a plurality of sequentially disposed < RTI ID = 0.0 > And to move a portion of the non-rigid material through the station. The first frame 1202 includes a first pair of sidewalls 1210 and 1212 positioned oppositely to each other and a second pair of sidewalls 1220 and 1212 facing each other and vertically positioned on the first pair of sidewalls 1210 and 1212 1214 and 1216 to form a substantially rectangular structure. The sidewalls 1210, 1212, 1214, 1216 may be formed from one or more wall portions that collectively form a substantially rectangular peripheral sidewall surrounding the center void (not shown). The center void (not shown) provides a material-free area with no interference by the first frame 1202.

In the exemplary embodiments, sidewalls 1210, 1212, 1214, and 1216 may be separate wall portions having respective distal portions cut at any other angle that allows attachment to each other to form a rectangular structure. Mechanisms for fastening the wall portions together may include a variety of screws or other fastening mechanisms known to those skilled in the art. It will be appreciated that the rectangular peripheral sidewalls collectively formed from the first and second pairs of sidewalls 1210, 1212, 1214 and 1216 may be formed as a continuous structure or from any number of wall portions. In addition, any mechanism for fastening the wall portions to one another may be utilized within the context of the present disclosure. It is contemplated that the mechanism for forming the first frame 1202 and / or securing the wall portions including the first frame 1202 is not intended to limit the aspects of the present disclosure in any way. Still further, it is understood that frames having substantially rectangular and other structures may be utilized in accordance with aspects of the present disclosure. Any and all such modifications and any combination thereof are contemplated as being within the scope of the present aspects.

Similar to the first frame 1202, the second frame 1204 includes a first pair of sidewalls 1220 and 1222 positioned opposite to each other and a second pair of sidewalls 1220 and 1222 facing each other and perpendicular to the first pair of sidewalls 1220 and 1222, And a second pair of sidewalls 1224, 1226 positioned to define a substantially rectangular structure. The sidewalls 1220,1222,1224,1226 may be formed from one or more structures that collectively form substantially rectangular peripheral sidewalls surrounding a central void (not shown) that provides a working area free of interference by the second frame 1204. [ May be formed from the wall portions. When assembling a plurality of wall portions to form a substantially rectangular peripheral wall, the wall portions may include adjacent attachment surfaces at any desired angle such that the wall portions to be joined form a rectangular structure. Mechanisms for fastening the wall portions together may include a variety of screws or other fastening mechanisms known to those skilled in the art. It will be understood and appreciated that the rectangular peripheral sidewalls collectively formed from the first and second pairs of sidewalls 1220, 1222, 1224, 1226 can be formed as a continuous structure or from any number of wall portions. In addition, any mechanism for fastening the wall portions to one another may be utilized within the context of the present disclosure. The mechanism for securing the formation of the second frame 1204 and / or the wall portions including the second frame 1204 is not intended to limit the aspects of the present disclosure in any way. Still further, it is understood that frames having substantially rectangular and other structures may be utilized in accordance with aspects of the present disclosure. Any and all such modifications and any combination thereof are contemplated as being within the scope of the present aspects.

The multi-frame production apparatus 1200 of FIG. 12 includes two frames 1202 and 1204, although aspects of the present disclosure consider any number of frames. For example, aspects of the present invention are equally applicable to a multi-frame manufacturing apparatus having three frames, four frames, five frames, and the like. The number of frames including multi-frame fabrication apparatus as generally described is not intended to limit the scope of aspects of the present disclosure.

As described above, the first frame 1202 and the second frame 1204 each move a large amount of non-rigid material through a plurality of sequentially disposed processing stations positioned in a conveyor- or assembly line-type arrangement . As such, the first frame 1202 includes a first moving mechanism 1230 coupled thereto and the second frame 104 includes a second moving mechanism 1232 coupled thereto. The first moving mechanism 1230 and the second moving mechanism 1232 each allow substantially horizontal movement in the front-rear direction, e.g., in the longitudinal direction 1268, between the pair of parallel side rails 1206 and 1208. Each of the first moving mechanism 1230 and the second moving mechanism 1232 includes a first frame 1202 and a second frame 1204 in the upper and lower directions, for example, in the longitudinal direction 1270 of the side rails 1206, Lt; RTI ID = 0.0 > vertical < / RTI >

The first moving mechanism 1230 is coupled to each of the opposing side walls 1210 and 1221 of the first pair of first frames 1202 and is coupled to the opposing side rails 1206 and 1208, Is configured to move cooperatively with the rails (1206, 1208). In embodiments, the first moving mechanism 1230 includes first and second side rails 1206, 1208 (not shown) to propel the first frame 1202 substantially vertically, as well as substantially vertically, Such as linear actuators, motors, and the like, that cooperate with one or more motion actuators. The second moving mechanism 1232 is coupled to each of the opposing side walls 1220 and 1222 of the first pair of second frames 1204 and is coupled to the opposing side rails 1206 and 1208, Is configured to move cooperatively with the side rails (1206, 1208). In the aspects, the second moving mechanism 1232 includes first and second side rails 1206, 1208 (not shown) to propel the second frame 1204 substantially vertically, as well as substantially horizontally, Such as linear actuators, motors, and the like. When the first moving mechanism 1230 and the second moving mechanism 1232 are operated, the two frames move in opposite horizontal directions so that their relative positions with respect to the manufacturing apparatus 1200 are switched, Allowing the frame 1204 to vertically pass over the first frame 1202 and / or allow the first frame 1202 to pass vertically onto the second frame 1204. [

The operations of the first moving mechanism 1230 and the second moving mechanism 1232 are such that the first frame 1202 and the second frame 1204 are switched positions relative to the sequentially disposed processing stations You may. It will be understood by those skilled in the art that the gripping mechanisms as described for the aspects shown in FIGS. 1-11 are included in the multi-frame manufacturing apparatus 1200 of FIG. 12 and function as described above.

As can be appreciated, aspects of the present disclosure are directed to multi-frame manufacturing apparatus for making articles, e.g., sock liners, formed of a non-rigid material. Embodiments of the present invention further relate to methods of making articles, such as sockliners, using a multi-frame manufacturing apparatus. A multi-frame manufacturing apparatus having a structure as described herein permits the interchangeability of the locations of a plurality of manufacturing frames which allows the processing of one or more articles to proceed while the material for the other article is being loaded into the apparatus. The multi-frame manufacturing apparatus having a structure as described herein allows further processing of a portion of the non-rigid material separated from the larger material stock, which portion remains untensioned during processing, Reduce waste caused by missing goods.

The method of manufacturing articles formed from non-rigid materials using a multi-frame manufacturing apparatus and a multi-frame manufacturing apparatus is described above with reference to specific aspects, but may be modified and modified without departing from the intended scope of protection provided by the following claims Can be achieved. It will be appreciated that any features and subcombinations are useful and may be utilized irrespective of other features and subcombinations. It is contemplated and within the scope of the claims.

When specific elements and steps are discussed in relation to one another, it should be understood that any element and / or steps provided herein may still be combined with any other elements and / or steps, . It should be understood that all of the elements shown in the accompanying drawings or described herein are to be interpreted as illustrative and not in a limiting sense, since many possible embodiments may be disclosed without departing from the scope thereof.

As used herein with respect to the claims listed below, the term "any claim" or similar variation of the term is intended to be construed so that the features of the claims may be combined in any combination. For example, an exemplary claim 4 may refer to a method / apparatus according to any of claims 1 to 3, characterized in that the features of claim 1 and claim 4 can be combined and the elements of claim 2 and claim 4 are combined The elements of claims 3 and 4 can be combined, the elements of claims 1, 2 and 4 can be combined, the elements of claims 2, 3 and 4 can be combined, 2, 3, and 4 may be combined, and / or interpreted to be other variations. It is also intended that the term "any claim" or similar variation of the term encompasses "any of the claims" or other variations of such terms, as indicated by some of the &

Claims (20)

As a manufacturing tool,
A first rectangular frame having at least one peripheral sidewall surrounding the first central void; And
A second rectangular frame having at least one peripheral sidewall surrounding the second central void
Wherein the two opposing sides of each of the first and second rectangular frames have a gripping mechanism for temporarily gripping the non-rigid material, and a gripping mechanism for temporarily gripping the non-rigid material, And a moving mechanism that allows at least one. 2. The tool of claim 1, wherein the gripping mechanism is a clamping mechanism having an open material receiving position and a closed material gripping position. The manufacturing tool according to claim 1 or 2, wherein the non-rigid material includes a stretching direction and a non-stretching direction, and the gripping mechanism grips the non-rigid material along the stretching direction. 4. The apparatus according to any one of claims 1 to 3, wherein each of the first and second parallel side rails includes a first track and a second track, and the moving mechanism of the first rectangular frame Is coupled with the first track and the movement mechanism of the second rectangular frame is coupled with the second track to allow horizontal and vertical movement. 5. The tool of claim 4, further comprising at least one linear actuator causing horizontal movement of the first rectangular frame and the second rectangular frame. 6. The tool of claim 5, further comprising at least one piston that causes vertical motion of the second rectangular frame. 7. The tool of claim 6, wherein the at least one linear actuator and the at least one piston cooperate with each other to allow the first rectangular frame and the second rectangular frame to switch positions. 8. A manufacturing tool according to any one of claims 1 to 7, further comprising a material loading mechanism for loading a non-rigid material in one of the first rectangular frame and the second rectangular frame. As a manufacturing tool,
A first frame having a first pair of sidewalls positioned facing each other and a second pair of sidewalls positioned opposite to each other and positioned vertically to the first pair of sidewalls to form a first rectangular structure;
A second frame having a first pair of sidewalls positioned facing each other and a second pair of sidewalls positioned opposite to each other and positioned vertically to the first pair of sidewalls to form a second rectangular structure; And
The first and second parallel side rails spaced apart from each other by a distance sufficient to allow the first and second frames to be movably positioned between the first and second parallel side rails,
Wherein the first frame and the second frame are movably positioned between the first and second parallel sidewalls so that substantially horizontal motion is allowed back and forth,
At least one of the first frame and the second frame being movably positioned between the first and second parallel side walls so that substantially vertical motion is allowed up and down,
Each side wall of the first pair of sidewalls of the first frame and a sidewall of each of the first pair of sidewalls of the second frame includes a gripping mechanism for temporarily gripping non-rigid material . 10. The apparatus of claim 9, wherein the gripping mechanisms of the first pair of sidewalls of the first frame and the first pair of sidewalls of the second frame comprise a clamping mechanism having an open material receiving position and a closed material gripping position, A manufacturing tool that is to be. 11. A manufacturing tool according to claim 9 or 10, wherein the non-rigid material comprises a stretching direction and a non-stretching direction, and the gripping mechanism grips the non-rigid material along the stretching direction. 12. A method according to any one of claims 9 to 11, wherein each of the first and second parallel side rails includes a first track and a second track, each of the side walls Wherein each of the sidewalls of the first pair of sidewalls of the second frame includes a first movement mechanism coupled with a first track of each of the first and second parallel side rails, And a second moving mechanism coupled with a second track of each of the second parallel side rails to permit horizontal and vertical motion. 13. A manufacturing tool according to any one of claims 9 to 12, further comprising at least one linear actuator causing substantially horizontal movement of the first frame and the second frame. 14. The tool of claim 13, further comprising at least one piston that causes a substantially vertical motion of at least one of the first frame and the second frame. 15. The manufacturing tool of claim 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 switch positions. 16. A manufacturing tool according to any one of claims 9 to 15, further comprising a material loading mechanism for loading a non-rigid material into one of the first frame and the second frame. A method of manufacturing using a multi-frame manufacturing apparatus,
Loading a non-rigid material from a loading station into a first rectangular frame, the first rectangular frame having opposing sides each comprising a gripping mechanism and a first moving mechanism;
Gripping the non-rigid material temporarily on the first rectangular frame;
Wherein said first moving mechanism moves said first rectangular frame substantially horizontally in a first direction and synchronously moves a second moving mechanism associated with a second rectangular frame substantially horizontally and substantially vertically in an opposite direction, The second rectangular frame and the first rectangular frame are moved
≪ / RTI > 18. The method of claim 17, wherein the gripping mechanism is a clamping mechanism having an open material receiving position and a closed material gripping position. 19. The method of claim 17 or 18, wherein the non-rigid material comprises a stretching direction and a non-stretching direction, and the gripping mechanisms grip the non-rigid material along the stretching direction. 20. A method according to any one of claims 17 to 19, wherein the first moving mechanism comprises at least one linear actuator causing horizontal movement of the first rectangular frame, At least one linear actuator causing horizontal motion and at least one piston causing vertical motion of the second rectangular frame.

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