Patent Description:
Some manufacturing processes require moving in-process work materials between physically distinct manufacturing stations. Such stations may perform sequential operations that require knowledge of the location of the materials, securement of the materials to prevent them from moving relative to the manufacturing station and/or relative to one another, and/or tensioning of the parts. These functions may be provided by stationspecific equipment, such as clips, pincers, pins or other devices associated with a particular station, possibly in conjunction with a vision system or human operator to help place or confirm the placement of landmarks on the work materials as needed at each manufacturing station. Alternately, these functions may be provided by a human or robotic operator that positions and maneuvers work materials at a particular station. These systems are cumbersome, complicated, and, particularly with human operators, prone to variation, error, and the possibility of injury.

<CIT> describes a system for manufacturing shoes including two or more pieces of equipment used in the customization and manufacturing of shoes and an alignment fixture that may engage with each piece of equipment by way of an alignment mounting member. The alignment fixture may secure to it a portion of a shoe, such as an upper portion, wherein the shoe portion remains in a flat position, and in a fixed relationship to the alignment fixture, throughout the various processes performed by the pieces of equipment. These pro-cesses may include, for example, printing, laser, embroidery, forming, cutting, or the like.

The present invention is defined by independent claim <NUM>. Additional aspects are defined in the dependent claims.

This disclosure generally relates to a manufacturing frame. The frame may be used to secure materials during a series of manufacturing operations. It may be necessary or convenient to use two or more distinct manufacturing stations. When work materials are moved, it may be necessary to determine the position of the work materials relative to a manufacturing station. For example, a manufacturing station comprising a quilting arm must be positioned relative to landmarks on the work materials, such as an edge of or an aperture in the work materials, to properly place a seam. As another example, a manufacturing station comprising a cutting tool must be positioned and oriented in a particular way relative to the work materials to properly cut the material to match a desired pattern. Similarly, it may be desired to keep the work materials at a particular tension. For example, it may be desired to keep the parts in a neutral tension, or slack, or taut.

The frame as disclosed can secure flexible work materials at a desired tension. The frame may be rigid and/or resistant to torsion, to prevent changes in tension and/or location of the work materials during manufacturing operations.

The frame includes an alignment tab. The alignment tab may have an alignment element that is configured to interact with a corresponding alignment element at a manufacturing station. The alignment elements cooperate to inform the manufacturing station of the position of the frame and the position of any material(s) on the frame. The alignment elements can therefore be used to define an origin for the manufacturing station, and to locate the work material(s) relative to that origin. In this way, the frame allows for the movement of the work material(s) between manufacturing stations without having to reassess the position of or reposition the work material(s) in order to continue sequential operations. The alignment elements may be sufficient to locate the work materials without visual inspection or repositioning of the work material(s).

These and other possible features of the claimed invention are described in further detail below.

This disclosure refers to the attached drawing figures, wherein:.

Working with flexible materials, such as non-woven materials, fabrics, and films, can be challenging during manufacturing. The materials can fold back on themselves or under themselves, drape in undesired ways, shift position, or otherwise thwart efforts to keep the parts in a particular spot or orientation during manufacturing. Movement of these materials can cause terminal defects in, for example, seams or joints between parts, cut lines, and aesthetics. For example, parts may be cut to the wrong shape or size if the material(s) are not positioned as intended relative to a cutting blade. As another example, a material in a stack of two or more materials might not be joined to any other material in the stack if the material has folded onto itself and does not pass under a sewing needle or quilting arm. An improperly positioned part that is glued or seamed out of position may be ugly or nonfunctional because of the misplacement.

Conventional efforts to maintain the position of small and/or flexible parts have been cumbersome, involving, for example, vacuum or suction-based securement of parts to a surface, the involvement of a human equipment operator, or expensive vision inspection systems. Some of these approaches may impede certain manufacturing techniques. For example, a surface equipped with vacuum or suction may be very large relative to the operating area of a particular piece of manufacturing equipment, such as a sewing machine. A solid, continuous surface may also create mechanical interference with some devices that require clearance under the work piece, or even prevent work on the backside of a work piece.

According to the claimed invention, a frame for use in manufacturing comprises a first frame. The first frame comprises a plurality of magnetic elements secured to the first frame. The first frame comprises a first plurality of pins secured to the first frame, wherein the first plurality of pins are positioned around the first frame for securing a material extending across a center area of the first frame. The first frame comprises a first aperture extending through the first frame. The frame comprises a second frame configured to coextensively mate with the first frame. The second frame comprises a second plurality of magnetic elements secured to the second frame. The first plurality of magnets and the second plurality of magnets are cooperatively positioned to magnetically attract the first frame and the second frame in the coextensively mated configuration. A solid portion of the second frame is configured to align with the first aperture of the first frame when in the coextensively mated configuration with the second frame. The frame comprises an alignment tab extending from the frame when the second frame is coextensively mated with the first frame. The frame comprises an ejection pin that is configured to separate the first frame from the second frame by pushing the first frame away from the second frame by applying pressure to the ejection pin. The frame may be rectilinear. The frame may comprise aluminum or steel. The first plurality of pins may comprise at least <NUM> pins. The first aperture may not extend through the second frame.

The manufacturing equipment and methods described could be used to manufacture a variety of products and intermediate components for products. For example, the manufacturing frame could be used to produce clothing, outerwear, wearable accessories such as hats and scarves, disposable articles such as shoe covers and rain ponchos, pillows and other home décor, and other products or product components that contain textiles, nonwoven fabrics, films or other thin, flexible materials. In some aspects, the equipment and methods may be used to produce shoes, and more particularly, shoe uppers.

Even for similar shoes, such as the sneakers depicted in <FIG>, the design of the upper may vary significantly from a manufacturing perspective. For example, although shoes <NUM>, <NUM>, <NUM>, <NUM> and <NUM> are similar in shape and structure, they have design elements that make different manufacturing processes necessary or convenient. For example, shoe <NUM> includes aesthetic elements, possibly stitching, printing, or added material, to form patterns under the ankle opening and at the toe-end of the shoe upper. In contrast, shoe <NUM> includes a more-or-less uniform fabric in most of the design of the shoe upper. Shoe <NUM> includes added materials forming a design at the heel and ankle-opening portions of the shoe upper. Shoe <NUM> includes contrasting materials sewn in to the toe-end of the shoe upper and along the mid-foot and ankle opening regions of the shoe upper. And shoe <NUM> includes a single material with a directional pattern assembled in small patches to create a multidirectional pattern across the shoe upper. Across these designs, the assembly processes vary, sometimes significantly, even though the general pattern for the shoe upper remains constant. Of course, with variation in the structure of the shoe-the positioning of the laces, shape and attachment of the tongue, presence or absence of piping, lining or edging, etc.-the number and magnitude of changes needed in the manufacturing process can increase rapidly.

<FIG> shows an exemplary manufacturing frame <NUM> that could be used, for example, to make a shoe upper or a portion of a shoe upper. Frame <NUM> comprises a top frame <NUM> and a bottom frame <NUM>. The top frame has a long side <NUM> and a short side <NUM>. The bottom frame has a corresponding long side <NUM> coextensive with top frame long side <NUM> and a corresponding short side <NUM> coextensive with top frame short side <NUM>. Because the frame as shown in <FIG> is rectilinear (or approximately rectilinear, since the corners are rounded), the top frame has a second long side 270a and a second short side 240a, and the bottom frame has a corresponding second long side 250a and a corresponding second short side 260a. However, the frame could have other shapes, including, without limitation, oval, square, triangular, irregular, etc..

Optionally, the frame <NUM> may further include a support structure <NUM> positioned between top frame <NUM> and bottom frame <NUM>. As shown, support structure <NUM> is a grid or mesh, which may facilitate certain manufacturing operations, such as needlework, like sewing, embroidery, edging, etc. Depending on the requirements of particular manufacturing process, it may be desirable to have a discontinuous surface, such as a grid or mesh or a surface with cut-outs that pass through portions of the area within the perimeter of the frame <NUM>. Under other circumstances, a solid support structure <NUM> may be desirable. For example, the support structure may facilitate heating (as by having a high effusivity, high heat transfer coefficient, or, conversely, a low thermal insulance, by induction heating, or otherwise) or cooling, or could serve as an anvil for sonic welding. As another example, the support structure may provide resistance for stamping or embossing operations. Under still other circumstances, no support structure <NUM> may be necessary or desirable. As described below, support structure <NUM> may be designed to facilitate creating a material within the frame <NUM>, as by additive deposition. In other aspects, the frame may be assembled with material <NUM> layered between the top frame <NUM> and the bottom frame <NUM>. The material <NUM> is shown layered over support structure <NUM> (i.e., closer to the top frame <NUM>), but could be positioned below support structure <NUM> (i.e., closer to the bottom frame <NUM>), or directly between top frame <NUM> and bottom frame <NUM>, if no support structure <NUM> is used. It should be understood that material <NUM> is described in the singular, but could be a laminate, distinct layers, or other mixes of materials, at the start of the manufacturing process or as the manufacturing process proceeds. Material <NUM> may be pliable. That is, if material <NUM> is suspended under its own weight, as in a fabric drape test, the material will not remain within ± <NUM>° of a plane.

Support structure <NUM>, if used, may be a conventional material that is incorporated into the product (that is, support structure <NUM> may be starting material <NUM>), or the support structure <NUM> may be destroyed in the course of processing material <NUM> and/or removing a finished part or part component from frame <NUM> and/or support structure <NUM>, or the support structure <NUM> may be a resuable structure that is not incorporated into the part or part component. An exemplary support structure <NUM> is a woven film of Teflon and/or glass. Additional non-limiting materials that might be suitable for use as a support structure include fiberglass, embroidery floss, polyester, organic cotton, nonwoven fabrics, or combinations thereof. If support structure <NUM> is a material with a low surface energy that might slip against gasket <NUM>, gasket <NUM> or gasket <NUM> (if used), support structure <NUM> may be joined, as by sewing, thermal bonding, adhesive bonding, etc., to an edge material with a higher surface energy or a textured surface that would be less likely to slip against the gasket.

As shown in <FIG>, the frame <NUM> may have a variety of embedded structures. For example, frame <NUM> comprises one and optionally more ejection pins <NUM>. In some aspects, ejection pins <NUM> may be present in top frame <NUM> or bottom frame <NUM>, or both the top frame <NUM> and the bottom frame <NUM>. As shown, bottom frame <NUM> comprises ejection pins <NUM> and top frame <NUM> does not. Reference numbers <NUM> highlight the flat surface of top frame <NUM> corresponding to the location of ejection pins <NUM>. In this way, applying pressure to the ejection pins <NUM> may separate the top frame from the bottom frame, by pushing the top frame away from the bottom frame.

Frame <NUM> may further include one or more alignment pins <NUM>. Alignment pins <NUM> may be present in the top frame <NUM>, or the bottom frame <NUM>, or in a complementary pattern on the top frame <NUM> and bottom frame <NUM> (to allow mating of the top frame <NUM> and bottom frame <NUM>). As shown, alignment pins <NUM> protrude from an upper surface of bottom frame <NUM>, and correspond to holes <NUM> in top frame <NUM>. This allows a lower surface of top frame <NUM> to sit flush against the upper surface of bottom frame <NUM> when alignment pins <NUM> are aligned with holes <NUM>. Holes <NUM> may, but do not have to, go completely through the thickness of top frame <NUM>. Rather, holes <NUM> should be approximately of the same height into top frame <NUM> as the height of alignment pins <NUM> from the upper surface of bottom frame <NUM>. The alignment pins <NUM> are shown as having the same shape and size as one another, but different alignment pins could be used. For example, alignment pins of different heights and/or cross-sections could be used to insure that the frames are oriented as desired. The placement of the alignment pins could also or alternatively differ along a side of the frame or along different sides of the frame. The spacing of the alignment pins could be uniform along a portion of the perimeter of the frame <NUM>, or along the entire perimeter of frame <NUM>, or could be irregular and/or asymmetric about a center line (along the x-axis or the y-axis) of the frame <NUM>.

Any desired number of alignment pins <NUM> could be used, from one pin or two pins for the entire frame to as many pins as dimensionally fit on the frame. In some aspects, the alignment pins <NUM> may be used to orient and/or help secure a flexible material inside the frame. For example, the material may have apertures or be processed to create apertures that fit over the alignment pins. In some aspects, a relatively high number of pins may be desirable, such as greater than <NUM> pins, or at least <NUM> pins, or <NUM> pins. For some working materials and manufacturing operations, as few as <NUM> pins might work, or <NUM> pins, or <NUM> pins. It may be desirable to place alignment pins <NUM> at intervals between <NUM> and <NUM> (inclusive of endpoints) around the perimeter of the frame <NUM>. If the intervals are irregular, it may be desirable to place the pins no more than <NUM> apart. If the pins are the primary securement mechanism for holding the material in place within the frame, a relatively high number of pins may help prevent the material from moving during manufacturing operations, where relatively small shifts in position-on the order of mm-could sometimes cause a defect in the product or product component. The alignment pins may also be used to align support structure <NUM>, if used. Alternately, support structure <NUM> could sit between bottom frame <NUM> and top frame <NUM> without seating support structure <NUM> on an alignment pin, particularly, but not exclusively, if support structure <NUM> is uniform throughout the area <NUM> within the frame <NUM> (e.g., a uniform mesh or grid, a uniform solid surface, etc.). Seating one or more apertures in support structure <NUM> on one or more alignment pins <NUM> may be more helpful where the support structure <NUM> is discontinuous or non-uniformly patterned, making the placement of the support structure <NUM> relative to the frame <NUM> more important for location determination, as described in further detail below. If the support structure <NUM> and/or working material <NUM> are seated on the alignment pins <NUM>, they may be seated on all of the alignment pins <NUM> present on frame <NUM>, or may be seated on only a subset of the alignment pins <NUM>. If both support structure <NUM> and working material <NUM> are seated on a subset of alignment pins <NUM>, they may be seated on the same subset of alignment pins <NUM>, or different subsets of alignment pins <NUM>, or overlapping subsets of alignment pins <NUM>.

The frame includes magnets <NUM>. Magnets <NUM> may be of opposite polarity in the top frame <NUM> and bottom frame <NUM>, and may tend to secure the top frame <NUM> to the bottom frame <NUM>. If magnets are used, it is desirable that they be of sufficient strength to hold the frame together during manufacturing processes. If the frame is to be reused, it is desirable that the magnets be of sufficiently limited strength that the top frame can be separated from the bottom frame to remove parts or spent materials after processing is complete. One of skill in the art will appreciate that these bounds depend on the particular processes used. For example, the magnets may need to be stronger for punching or embossing operations than for some cutting or needlework operations. As another example, relatively weaker magnets may be desirable if the frames are opened by hand by a human operator than if the frames are opened using a pneumatic tool or machine. The number and spacing of the magnets can also be varied to achieve the desired attraction of the bottom frame <NUM> to the top frame <NUM>. Alternatives to magnets could serve as closures for the frame <NUM>, including, without limitation, screws, bolts-and-nuts, clamps, ties, anchors, hook-and-loop tape, adhesives, and the like. Magnets have been found to be amenable to efficient, automated frame assembly and disassembly, as described in further detail below.

As shown in <FIG>, frame <NUM> may comprise one or more stand-offs <NUM>. Stand-offs <NUM> may be used to create a fixed distance at the junction <NUM> between top frame <NUM> and bottom frame <NUM> when the top frame <NUM> are in a mated configuration (as shown in <FIG>). The use of stand-offs <NUM> to create a fixed space prevents the material <NUM> and/or support structure <NUM> from defining the spacing between the frames, giving a consistent frame structure. The distance created by the stand-off could be greater than <NUM> and less than <NUM>, or between <NUM> and <NUM> (inclusive of endpoints) or greater than <NUM>, depending on the nature of the materials <NUM> and/or support structure <NUM> being used in the frame. In different manufacturing processes or with different materials, different stand-offs <NUM> could be used with what is otherwise the same frame <NUM>.

As shown in the exploded view of the top surface of bottom frame <NUM> in <FIG>, the frame may comprise a gasket <NUM>. The gasket is shown on the top surface of bottom frame <NUM>, however, the gasket <NUM> could be attached to the bottom surface of top frame <NUM>, or there could be a gasket <NUM> on both the top surface of bottom frame <NUM> and the bottom surface of top frame <NUM>. The gasket may be compressible, and may serve to help secure a support structure <NUM> and/or working material <NUM> within the frame. Alternately or additionally, as shown in <FIG>, the top frame <NUM> (or bottom frame <NUM>, not shown) may have a groove or indentation <NUM> along an outer surface of the frame. A gasket <NUM> may be configured to sit in a press-fit configuration in the indentation <NUM>, as shown in <FIG>. A portion of support structure <NUM> and/or working material <NUM> may wrap at least partially around the outer surface of frame <NUM>, and the gasket <NUM> may sit over the support structure <NUM> and/or working material <NUM> within the indentation <NUM>, as shown in <FIG>. Gasket(s) <NUM> and/or <NUM> may be used to help secure support structure <NUM> and/or working material <NUM>, and may help to regulate the tension on the working material <NUM> during manufacturing operations. A gasket may be particularly useful, but not exclusively useful, for securing working material <NUM> where a relatively low number of alignment pins are used, or where working material <NUM> may be prone to ripping or unraveling if apertures are made in working material <NUM> to accommodate one or more alignment pins <NUM>. In some embodiments, a single part frame <NUM> (i.e., without separate top and bottom frames) may be used with a gasket as shown in <FIG> to secure material <NUM> and/or support structure <NUM> to the frame <NUM>, or, alternatively, the bottom frame <NUM> may in some instances be used without a top frame <NUM> by securing material <NUM> and/or support structure <NUM> to the bottom frame <NUM> using gasket <NUM>. The gasket <NUM> in <FIG> is shown as a solid rod, but could be hollow (e.g., a tube), and could be continuous or discontinuous around the perimeter of the frame <NUM>. Any suitable material may be used for gasket <NUM> (or gasket <NUM> or gasket <NUM>) including, without limitation, rubber (including latex, BUNA and nitrile rubber), polypropylene, silicone, metal, foam, neoprene, PTFE, polycarbonate, vinyl, polyethylene, nylon, PVC, TPU, polyisoprene, and combinations thereof.

As depicted in <FIG> and <FIG>, an alignment tab <NUM> extends from the bottom frame <NUM>. The alignment tab <NUM> could extend from the top frame <NUM> or the bottom frame <NUM> or could be positioned between the frames and secured in place by a gasket <NUM> or <NUM>, or could be secured in place by a press-fit around one or both of the top frame <NUM> and the bottom frame <NUM>, or could be otherwise secured to the assembled frame (e.g., by screws, bolts, adhesives, putty, magnets, etc.). The alignment tab <NUM> includes at least one alignment element, and, as shown, includes two alignment elements 340a, 340b on the alignment tab <NUM>. Alignment elements on the same tab may be of the same or different types (e.g., pins, apertures, other mechanical fasteners, adhesives, hook-and-loop fasteners, etc.) and the alignment elements on different tabs on the same frame may be of the same or different types.

More than one alignment tab <NUM> may be used, with each alignment tab <NUM> having at least one alignment element. If more than one alignment tab <NUM> is used, additional alignment tabs may extend from the same side of the frame (e.g., long side <NUM>, opposite long side 270a, short side <NUM>, opposite short side 240a, or corresponding sides of bottom frame <NUM>), or from a different side of the frame, or from all sides of the frame. If placed on the same side, two or more alignment tabs <NUM> may be placed near opposite ends of that side. For example, a first alignment tab on long side <NUM> or <NUM> may be placed near short side <NUM> or <NUM>, such as within <NUM> of the short side, or within <NUM> of the short side, or within <NUM> of the short side. A second alignment tab on long side <NUM> or <NUM> may be placed near short side 240a or 260a, such as within <NUM> of the short side, or within <NUM> of the short side, or within <NUM> of the short side. If more than one alignment tab is used, the alignment tabs may be of the same structure, and may be oriented similarly or differently (e.g., protrusion up, protrusion down, protrusions sideways, aperture up, aperture down, aperture sideways). If more than one alignment tab is used, the alignment tabs and/or their alignment elements may be symmetrical about a centerline (in the x-direction or in the y-direction) of the frame <NUM>, or may be positioned asymmetrically.

The alignment element may protrude from the alignment tab <NUM>. For example, the alignment element may be a pin or rod. Less pronounced protrusions should also work, however, a pin or rod may allow for additional precision in engaging the alignment element. Alternately, the alignment element may be an aperture or discontinuity in the surface of the alignment tab <NUM>. The alignment element on alignment tab <NUM> may be engaged by an alignment element on a manufacturing station. For example, as shown in <FIG>, a frame <NUM> may have two alignment tabs 330a, 330b, with alignment elements corresponding to alignment elements 520a, 520b on manufacturing station <NUM>. Where the alignment element on alignment tab is a protrusion, the alignment element on the manufacturing station may be an aperture, discontinuity, or hole in the surface of manufacturing station, sized and configured to receive or engage the protrusion on alignment tab <NUM>. Where the alignment element on alignment tab <NUM> is an aperture or discontinuity, the alignment element(s) 520a, 520b, as shown on manufacturing station <NUM>, may be protrusions, such as a pin or rod, sized and positioned to engage the aperture or discontinuity on alignment tab <NUM>. Other corresponding alignment elements could be used to engage the alignment elements on the alignment tab and the manufacturing station, including hook-and-loop fasteners, selective adhesives (including cohesives), nuts-and-bolts, screws, and the like. Pin-based engagement systems have the advantages of being relatively precise-an aperture can be sized and shaped to receive a specific pin and to hold the position of the pin with little variation-and relatively fast to engage and disengage-the pin is positioned over an aperture (or vice versa) and dropped or slid into place, or lifted out of or away from the aperture to disengage.

The frame <NUM> may be prepared for use in a manufacturing process as depicted in <FIG>. The frame <NUM> could be prepared manually, by a human operator. However, it may be desirable to prepare the frame using an automated process. In this case, frame <NUM> may be placed in an assembly/disassembly machine, shown as step <NUM> in assembly/disassembly process <NUM>. The alignment tab <NUM> on frame <NUM> may be engaged by an alignment element on the assembly/disassembly machine, shown as step <NUM>. At step <NUM> pins in the assembly/disassembly machine, configured to align with one or more ejection pins <NUM> in frame <NUM>, may rise to separate top frame <NUM> from bottom frame <NUM>, e.g., by exceeding the attractive force of magnets <NUM> in frame <NUM>. If alternate closures are used, an additional and/or simultaneous step may be required to disengage the closure, e.g., by unscrewing screws or bolts, untying ties, unclamping clamps, etc..

At step <NUM>, the top frame <NUM> is removed from the bottom frame <NUM>. The top frame <NUM> is removed from the bottom frame <NUM> in that lower surface of the top frame <NUM> is distanced from the bottom frame <NUM>. In some circumstances, this distance might just enough to remove or add materials between the top frame <NUM> and the bottom frame <NUM>. In other circumstances, the top frame <NUM> could be moved away from the bottom frame <NUM>, or vice versa, or even temporarily removed from the assembly/disassembly machine. At step <NUM>, any material <NUM> and/or support structure <NUM> remaining in the frame from prior manufacturing operations, and which are no longer desired within the frame, may be removed from the frame, including alignment pins <NUM>, if the material <NUM> and/or support structure <NUM> is engaged with the alignment pins <NUM>. The materials removed may be the finished product or product component from prior manufacturing operations, or may be waste from prior manufacturing operations (e.g., if the finished product or product component was removed from the frame at a manufacturing station prior to moving the frame to the assembly/disassembly machine). Of course, if the frame is new or has no materials inside the frame, step <NUM>, and potentially steps <NUM> and <NUM>, may be unnecessary.

At step <NUM>, new material <NUM> and/or support structure <NUM> may be placed in the frame. Placing the material <NUM> and/or support structure <NUM> in the frame may include seating the material <NUM> and/or support structure <NUM> on one or more alignment pins <NUM> in frame <NUM>. If the support structure <NUM> from prior manufacturing operations is to be used again, the support structure <NUM> may remain in place during the assembly/disassembly processes. If the support structure <NUM> is intended to remain in place during assembly/disassembly of the frame, support structure <NUM> may have ejection pins or holes corresponding to frame <NUM> to facilitate the opening of the frame <NUM>, or, alternatively, may have holes or cut-outs (e.g., irregularities in the perimeter of the support structure <NUM>) so that the support structure is not present near the ejection pins or holes and does not interfere with opening the frame.

Once new material <NUM> and/or support structure <NUM> are placed on the frame, the top frame <NUM> is mated to the bottom frame <NUM> (if a top frame <NUM> is used). That is, top frame <NUM> may be placed on top of alignment pins <NUM> in bottom frame <NUM>, or, alternatively, alignment pins <NUM> in top frame <NUM> may be placed on the bottom frame <NUM>. The top frame <NUM> may be pressed against the bottom frame <NUM>. This pressing may be used to compress any gaskets <NUM>, material <NUM>, and/or support structure <NUM> between the top frame <NUM> and the bottom frame <NUM> sufficiently to engage the closure system that will hold the top frame <NUM> and bottom frame <NUM> together during manufacturing operations (e.g., magnets <NUM>). In some configurations, it will not be necessary to press the top frame <NUM> and bottom frame <NUM> together. For example, a magnet or tie-based closure system may pull the frame components together without exerting separate forces on the frame.

The top frame <NUM> may fit into bottom frame <NUM> using a tongue-and-groove structure, as shown in <FIG>. As shown, a tongue <NUM>, shown on top frame <NUM>, fits into a groove <NUM> on bottom frame <NUM>. However, the tongue could be placed on the bottom frame <NUM> and the groove placed on the top frame <NUM>. An inner gasket <NUM> may be placed within the groove <NUM>. When tongue <NUM> is placed into groove <NUM> over material <NUM> and/or support structure <NUM>, inner gasket <NUM> is compressed, exerting a force that tends to press material <NUM> and/or support structure <NUM> against the tongue <NUM>, holding the material <NUM> and/or support structure <NUM> in place. The inner gasket <NUM> is shown on one side wall of groove <NUM>, but could be placed on the opposite sidewall of groove <NUM>, or separate gaskets could be placed on each of the sidewalls of groove <NUM>. Alternately or additionally, gasket <NUM> could be placed at the bottom of the groove <NUM>, however, such a gasket may tend to apply an upward force against the tongue <NUM> (or a downward force against tongue <NUM>, if tongue <NUM> is disposed on the bottom frame <NUM>), and the press-fit, magnets, ties or other closures used to secure the frames together might need to be adjusted to accommodate that upward pressure to prevent the frames from tending to separate. Alternately, inner gasket <NUM> could be placed on a surface of the tongue <NUM>, either side, both sides, bottom, or all three sides of tongue <NUM> that are placed in groove <NUM>.

If a gasket <NUM> around an outer edge of frame <NUM> is used, it may be secured to the outer edge at step <NUM>. Securing the gasket may involve wrapping portions of material <NUM> and/or support structure <NUM> around the frame <NUM>. As noted above, gasket <NUM> could be placed in an indentation <NUM> in frame <NUM> over the wrapped portions of material <NUM> and/or support structure <NUM>. Securing gasket <NUM> may be in addition to or in lieu of seating the new material <NUM> and/or support structure <NUM> on alignment pins <NUM> at step <NUM>.

When the new material <NUM> and/or support structure <NUM> are secured and the frame <NUM> is closed, the assembly/disassembly machine may disengage the alignment tab <NUM>. The frame <NUM> can be removed, manually or mechanically, from the assembly/disassembly machine.

An assembled frame <NUM> ready for manufacturing operations is shown in <FIG> with new material <NUM> secured in the frame <NUM>. A support structure (not shown) may also be present. Alternately, a support structure <NUM> may be present with no new material <NUM>. For example, the support structure <NUM> may be used during additive deposition operations, such as 3D printing, extrusion, spray deposition, etc., such that a material <NUM> is not originally present in the frame, but is deposited on the support structure <NUM> as part of the manufacturing operations performed with the frame <NUM>. Of course, other materials could be placed on support structure <NUM> as part of the manufacturing operations, for example, lying textile components on the support structure as part of a manufacturing operation.

The assembled frame <NUM> is shown in <FIG> with alignment tabs 330a and 330b on opposing long sides of the frame (e.g., long sides <NUM>, 270a and/or <NUM>, 250a). The alignment tabs could be placed in any location convenient for the manufacturing processes. In some circumstances, it may be desirable to space the alignment tabs apart from one another, to prevent the alignment tabs from jointly serving as a single point about which the frame <NUM> could rotate. In other circumstances, only one alignment tab may be used. The alignment tabs 330a and 330b interaction with alignment elements 520a and 520b at manufacturing station <NUM>. As shown, alignment tabs 330a and 330b comprise apertures, and alignment elements 520a and 520b comprise raised protrusions from a surface of the manufacturing station <NUM> that can fit into the apertures on alignment tabs 330a and 330b. Alternately, alignment tabs 330a and 330b could comprise protrusions that fit into apertures on manufacturing station <NUM>. Or alignment tabs 330a and 330b and alignment elements 520a and 520b could comprise any compatible, reversibly joinable systems, such as bolt-and-nut, screws, pins, hook-and-loop, adhesives (particularly, but not exclusively, selective adhesives, such as cohesives), clamps, press-fit mechanisms, and the like. If more than one alignment tab is used, different joining systems can be used with different tabs. For example, a first alignment tab 330a could include a protruding pin, and a second alignment tab 330b could include an aperture. As another example, a first alignment tab 330a could include a press-fit mechanism and a second alignment tab 330b could include a screw.

When the alignment tabs 330a, 330b on frame <NUM> are engaged with the alignment elements 520a, 520b at the manufacturing station <NUM>, the frame is positioned in a known location and orientation relative to the manufacturing station <NUM>, as shown in <FIG>. Without additional inspection or adjustment, a manufacturing operation can be performed with confidence in the location of the frame <NUM>, and, indirectly, in the location of a material <NUM> and/or support structure <NUM> secured in the frame <NUM>. As shown, manufacturing station <NUM> comprises a quilting arm <NUM>, which could be used for seaming, embroidery, quilting, or other needlework. Such needlework can be positioned on material <NUM> with high precision based on the known location and orientation of the frame. If desired, a vision inspection system and/or human operator can verify the position of the frame <NUM>, the position of the work material <NUM>, and/or the quality of the outcome of a particular manufacturing operation. However, use of the vision inspection system and/or human operator inspection should not be required to confirm the location or orientation of the frame <NUM> or materials, and may be omitted, or may be used intermittently, e.g., on randomly selected parts, or on a part at arbitrary time or quantity intervals. If desired, a vision inspection system can be incorporated into a standalone manufacturing station (e.g., the manufacturing operation at that manufacturing station is visual inspection), or can be added as a supplemental piece of equipment and functionality to a manufacturing station that performs another manufacturing operation (apart from the visual inspection).

<FIG> depict how frame <NUM> may be used in a series of manufacturing operations. Assembled frame <NUM> is engaged with a first manufacturing station <NUM>. As shown in <FIG>, the first manufacturing station <NUM> comprises a rotary cutting tool <NUM>. Also shown are a second manufacturing station <NUM> comprising placement arms <NUM> (<FIG>), and a third manufacturing station <NUM> comprising quilting arm <NUM> (<FIG>). The nature of the manufacturing operation at a particular manufacturing station, and the order in which the frame is delivered to various manufacturing stations, can be varied based on the product or product component being manufactured. Non-limiting examples of manufacturing operations include placement (e.g., deliberate repositioning of the materials, or the placement of new materials within the frame, possibly in addition to materials already in the frame), joining (needlework, adhesive application, thermal bonding, high frequency welding, ultrasonic welding, sonic welding, etc.), decoration (dying, dye sublimation, digital printing, pad printing, heat transfer, painting, spray painting, embellishing, needlework, etc.), dispensing (e.g., of adhesives or embellishments, like rhinestones or glitter), cutting, cleaning, tufting, texturizing, polishing, or the like. Different operations can be combined at a single manufacturing station. For example, a material may be joined and then cut-to-shape, or cut-to-shape and then serged, without being moved between physically separate manufacturing stations.

Frame <NUM> engages with manufacturing station <NUM> using alignment tabs <NUM> (shown in <FIG> extending from the same side of frame <NUM>). The engagement with the alignment tabs confirms that the frame <NUM> is in a known and stable position at manufacturing station <NUM>. Using data about the size of the frame, the materials involved, and any prior manufacturing operation(s), the manufacturing station can define an origin relative to the frame, or determine the position of the frame relative to an arbitrary origin, and proceed to perform location-specific processes without having to separately confirm the position of the material <NUM> inside the frame <NUM>. That is, the position of a manufacturing operation can be precisely determined with visually or mechanically determining the position of the material <NUM>.

When the frame <NUM> is removed from manufacturing station <NUM>, material <NUM> has been modified to in-process material <NUM>, which in this case has been cut partially (e.g., scored) from material <NUM>, as shown in <FIG>. Frame <NUM> with in-process material <NUM> may be transferred to a second manufacturing station <NUM>, as shown in <FIG>. The alignment tab or tabs on frame <NUM> are then engaged with alignment elements at manufacturing station <NUM>. As before, manufacturing station <NUM> can deduce the positon of in-process material <NUM> without direct, visual or mechanical confirmation. When the manufacturing operation at manufacturing station <NUM> is complete, manufacturing station <NUM> disengages the alignment tabs of frame <NUM>, which now secures in-process material <NUM>. Frame <NUM> is moved to manufacturing station <NUM>, where manufacturing station <NUM> engages the alignment tab or tabs on frame <NUM>, and performs a manufacturing operation, as shown in <FIG>. In this example, manufacturing station <NUM> provides needlework incorporating a layer added to in-process material <NUM> at manufacturing station <NUM>, resulting in in-process material <NUM>. When the manufacturing operation at manufacturing station <NUM> is complete, manufacturing station <NUM> disengages the alignment tab(s) of frame <NUM>, which can then be used to transfer in-process material <NUM> to manufacturing station <NUM>, as shown in <FIG>.

Manufacturing station <NUM> may comprise a further manufacturing operation. Manufacturing station <NUM> may comprise a removal and/or inspection station, where a completed product or product component is removed from frame <NUM>, possibly by cutting a product or product component away from a portion of the original material <NUM>. Alternately or additionally, manufacturing station <NUM> may comprise an assembly/disassembly machine to remove the product, product component, and/or non-product remnant materials. Manufacturing station <NUM> may represent a series of further manufacturing operations, in which each manufacturing station engages the alignment tabs on frame <NUM>, performs a manufacturing operation, and disengages the alignment tabs.

<FIG> show how materials may stack up on a manufacturing frame. For example, a support structure <NUM> may be used. A first layer <NUM> may be pre-cut and placed or cut and placed at a first manufacturing station, as yielded in-process material <NUM>. A second layer <NUM> may be placed at a second manufacturing station, as yielded in-process material <NUM>. A needlework operation at a third manufacturing station may leave stitches <NUM>, as yielded in-process material <NUM>. As described below, manufacturing may occur on both faces of the frame <NUM> and material <NUM>, making it possible to have a fourth layer <NUM> under support structure <NUM>. In this particular example, support structure <NUM> may be removable, e.g., by tearing, dissolving, breaking, melting, or subliming support structure <NUM> when support structure <NUM> is no longer needed. Support structure <NUM> may be frangible, sacrificial or dissolvable. Support structure <NUM> could also have part lines, gaps, apertures, or the like that would allow the finished part or part component to be removed from the support structure <NUM>. Layers <NUM>, <NUM>, <NUM> and <NUM> combine to form stack <NUM>, as shown in <FIG>, which in this example was joined together by stitches <NUM>.

<FIG> shows an exemplary stack of materials from a top view, where material <NUM> is the base material originally layered in the frame prior to manufacturing. As other layers are added, material <NUM> remains visible from the top of the stack in areas 800a and 800b. The stack may include a structural reinforcement layer <NUM>, which shows through overlying layers near the center of the product. The stack may include a decorative layer <NUM>, which adds color or visual variety to the design of the product. Layer <NUM> could also have structural features, such as stretch, or stretch resistance, or abrasion resistance, or tear resistance. As a result of the layering of complex shapes of distinct materials, an elaborate aesthetic appearance is created from just three layers of materials. Variations in the color or shape of any of the layers can make a significant change in the appearance of the product or product component, in this example, a shoe upper. And the layers can be positioned relative to one another during manufacture without direct visual confirmation or mechanical alignment using the location of the frame <NUM> as determined from one or more alignment tabs <NUM>.

As mentioned above, a frame as described can facilitate manufacturing operations from both faces of the frame, or, stated differently, on both faces of a material <NUM> or support structure <NUM> secured within the frame <NUM>. A process for manufacturing on both faces of a material is outlined in <FIG> and depicted in <FIG>. At step <NUM>, an assembled frame <NUM> is positioned at a first manufacturing station <NUM>. As shown, an up-face <NUM> of the frame (and a corresponding up-face <NUM> of the material <NUM> within the frame <NUM>) faces up at the first manufacturing station <NUM> (<FIG>). In this sense, the face that the first manufacturing station operates upon may be the up-face, since the frame could just as easily be positioned at the first manufacturing station with the bottom frame <NUM> facing up or the top frame <NUM> facing up. The frame <NUM> is aligned with the first manufacturing station <NUM> by engagement of the alignment tab(s) <NUM> on the frame <NUM> at step <NUM>. A first manufacturing operation is performed on the first face of the material at step <NUM>. While the first operation is performed on (or from) the first face of the material, it should be understood that the first operation may still contact or affect the second face of the material. For example, needlework may transcend both faces, and cutting through a material might also work both faces of the material. When the first manufacturing operation is complete, the manufacturing station disengages the alignment tab(s), and the frame can be removed from the first manufacturing station <NUM>.

The frame <NUM> can be positioned at a second manufacturing station, shown as step <NUM>. At the second manufacturing station, the frame <NUM> may be positioned with the up-face <NUM> of the frame up 950a (<FIG>), or with the up-face <NUM> down 950b (<FIG>). As at the first manufacturing station <NUM>, the frame <NUM> is aligned with the second manufacturing station by engagement of the alignment tab(s) <NUM> on the frame <NUM> at step <NUM>. A second manufacturing operation is performed on the second face <NUM> of the material at step <NUM>. If the up-face <NUM> is facing up, this may involve a manufacturing station <NUM> configured to work from underneath the frame <NUM> (<FIG>). If the up-face <NUM> is facing down, this may involve a manufacturing station <NUM> configured to work on whatever surface is currently facing up (<FIG>). In either way, the second face <NUM> or down-face of the material can be worked without removing the material <NUM> from the frame <NUM>. The alignment tab(s) <NUM> on the frame <NUM> are disengaged, and the frame <NUM> can be removed from the second manufacturing station <NUM> or <NUM>. Additional manufacturing operations can be performed on either face of the material, as desired. This may include adding layers to one or both faces, adding surface decoration or treatment (e.g., tufting, polishing, abraiding, adding glitter, painting or dying, etc.), or processes which affect both faces of the material from one face, such as cutting through the material(s) or some needlework operations.

It will be understood that certain features and subcombinations are of utility and may be employed without reference to other features and subcombinations. Provided it is within the scope of the claims.

Claim 1:
A frame (<NUM>) for use in manufacturing, the frame (<NUM>) comprising: a first frame (<NUM>) comprising: a first plurality of magnets (<NUM>) secured to the first frame; a first plurality of pins (<NUM>) secured to the first frame, wherein the first plurality of pins are positioned around the first frame for securing a material (<NUM>) extending across a center area of the first frame; a first aperture extending through the first frame; a second frame (<NUM>) configured to coextensively mate with the first frame, the second frame comprising: a second plurality of magnets (<NUM>) secured to the second frame, wherein the first plurality of magnets and the second plurality of magnets are cooperatively positioned to magnetically attract the first frame and the second frame in the coextensively mated configuration; a solid portion of the second frame configured to align with the first aperture of the first frame when in the coextensively mated configuration with the second frame; an alignment tab (<NUM>) extending from the frame (<NUM>) when the second frame is coextensively mated with the first frame; and an ejection pin (<NUM>) that is configured to separate the first frame from the second frame by pushing the first frame away from the second frame by applying pressure to the ejection pin.