Patent ID: 12225983

DETAILED DESCRIPTION

Some manufacturing operations are location-sensitive. For example, when seaming two materials together, if the materials are skewed from the intended position, the seam might not catch both or all of the materials intended to be seamed together, or the placement of the seam might be unattractively skewed from the intended aesthetic design. Similarly, if the materials are positioned properly, but the seam is misplaced, the seam may be functionally or aesthetically unacceptable. Similar problems arise with other joining processes, cutting processes, surface treatments, etc. These problems are compounded when a series of operations are performed, because small variances can stack up through the series of operations to create defects at later operations. These problems are further compounded when the series of operations are performed at physically distinct manufacturing stations, where alignment and position change with each move between stations.

Conventional efforts to maintain precise position and alignment of materials, and to align manufacturing operations to the materials, have typically involved either visual inspection or mechanical inspection or added manipulation of the materials. For example, a machine or human visual check may ensure that the materials are where they are expected to be, or a manufacturing station may have a built in mechanical gage, such as a rail that a particular portion of material is pushed flush against, or the parts may be specifically positioned, by human or machine manipulation, for a particular operation. All of these compensation mechanisms add cost to the process. Machine-implemented solutions, particularly mechanical gages, are also tailored to a part as it should arrive at a particular manufacturing station. For example, if two layers cut into star shapes are to be seamed together, the gauge or rail may have a zig-zag pattern to accommodate the star points. If the order of operations changes—say the layers are to be joined and then cut into star shapes—then the mechanical gauge has to be reconfigured. Even a predictable or repeated variation in the order of operations requires physically reconfiguring the manufacturing equipment.

In some aspects, a manufacturing system is disclosed. The manufacturing system comprises a first manufacturing station configured to perform a first manufacturing operation. The manufacturing system comprises a first securing member at the first manufacturing station. The first securing member secures a frame at a known location at the first manufacturing station. The manufacturing system comprises a second manufacturing station configured to perform a second manufacturing operation. The manufacturing system comprises a second securing member at the second manufacturing station. The second securing member secures the frame at a known location at the second manufacturing station. The first securing member and the second securing member are configured to engage with an alignment tab on the frame, such that a position of a material maintained by the frame is known relative to both the first manufacturing station and the second manufacturing station when the first securing member and the second securing member secure the frame respectively.

The material maintained by the frame may be pliable. The frame may comprise a perimeter structure and a support structure within the perimeter structure. The support structure, if present, may be discontinuous. The support structure may be joined to the material maintained by the frame at one or more manufacturing stations. The support structure may be removed from the material maintained by the frame at a manufacturing station. The support structure may be frangible, sacrificial or dissolvable. Each of the manufacturing stations may have an origin determined by reference to the alignment tab and independent of the origin of the other manufacturing stations. The material maintained by the frame may be reversibly joined to the frame without piercing the material. The material maintained by the frame may be reversibly joined to the frame using a gasket-based securement.

In some aspects, a method of manufacturing an article with pliable material is disclosed. The method comprises positioning a first article secured in a frame at a first manufacturing station. The first article is aligned at the first manufacturing station with an alignment tab on the frame removably secured to the first manufacturing station. The method comprises performing a first manufacturing operation at a first location on the first article at the first manufacturing station. The method comprises positioning the first article secured in the frame at a second manufacturing station. The first article is aligned at the second manufacturing station with the alignment tab on the frame removably secured to the second manufacturing station. The method comprises performing a second manufacturing operation at the first location on the first article at the second manufacturing station. The first operation and the second operation are performed at the first location as a result of the known position of the first location relative to the alignment tab of the frame.

The method may further comprise securing the article in the frame. Securing the article in the frame may comprise positioning a pliable material within the frame. Positioning a pliable material within the frame may comprise additive deposition of a material on a support surface within a perimeter of the frame. The method may further comprise removing the article from the frame. Positioning a pliable material within the frame may comprise tensioning the pliable material.

In some aspects, a method of manufacturing a variety of products is disclosed. The method comprises providing a plurality of manufacturing stations, the manufacturing station configured to perform two or more different manufacturing operations. Each of the plurality of manufacturing stations comprises a securement mechanism for releasably engaging an alignment tab. The method comprises providing a plurality of frames, each of the frames configured to support a material or a set of materials. The plurality of frames each comprise at least one alignment tab. The method comprises performing a first series of manufacturing operations on a first subset of the set of materials to yield a first set of manufactured products. The method comprises performing a second series of manufacturing operations on a second subset of the set of materials to yield a second set of manufactured products. The first set of manufactured products differs from the second set of manufactured products in at least one of material content or structure. The manufacturing operations each comprise aligning the alignment tab on one of the plurality of frames with the securement mechanism on the manufacturing station, modifying the material on the frame, and removing the alignment tab on the frame from the securement mechanism on the manufacturing station.

The first series of manufacturing operations may be performed at the same manufacturing stations as the second series of manufacturing operations, in a different order than the second series of manufacturing operations. A starting material in the first series of manufacturing operations may be the same as the second series of manufacturing operations. The manufactured products may be shoe uppers.

The manufacturing methods and equipment 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, non-woven fabrics, films or other thin, pliable 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 inFIG.1, the design of the upper may vary significantly from a manufacturing perspective. For example, although shoes100,120,140,160and180are similar in shape and structure, they have design elements that make different manufacturing processes necessary or convenient. For example, shoe100includes 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, shoe120includes a more-or-less uniform fabric in most of the design of the shoe upper. Shoe140includes added materials forming a design at the heel and ankle-opening portions of the shoe upper. Shoe160includes 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 shoe180includes a single material with a directional pattern assembled in small patches to create a multi-directional 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.2shows an exemplary manufacturing frame230that could be used, for example, to make a shoe upper or a portion of a shoe upper. Frame230comprises a top frame200and a bottom frame220. The top frame has a long side270and a short side240. The bottom frame has a corresponding long side250coextensive with top frame long side270and a corresponding short side260coextensive with top frame short side240. Because the frame as shown inFIG.2is rectilinear (or approximately rectilinear, since the corners are rounded), the top frame has a second long side270aand a second short side240a, and the bottom frame has a corresponding second long side250aand a corresponding second short side260a. However, the frame could have other shapes, including, without limitation, oval, square, triangular, irregular, etc. The long side270, second long side270a, short side240, and second short side240aof the top frame200form a perimeter of top frame200. The long side250, second long side250a, short side260, and second short side260aof the bottom frame220form a perimeter of bottom frame220. When the top frame200is coextensively mated to the bottom frame220, the perimeters of the top frame200and bottom frame220together form the perimeter of the frame230.

Optionally, the frame230may further include a support structure210positioned between top frame200and bottom frame220. As shown, support structure210is 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 frame230. Under other circumstances, a solid support structure210may 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 structure210may be necessary or desirable. As described below, support structure210may be designed to facilitate creating a material within the frame230, as by additive deposition. In other aspects, the frame may be assembled with material205layered between the top frame200and the bottom frame220. The material205is shown layered over support structure210(i.e., closer to the top frame200), but could be positioned below support structure210(i.e., closer to the bottom frame220), or directly between top frame200and bottom frame220, if no support structure210is used. Support structure210may be joined to material205during the manufacturing process. If joined to material205, support structure210may be removed from material205during later processing. For example, support structure210may be frangible, sacrificial or dissolvable. Support structure210, if used, may be a conventional material that is incorporated into the product (that is, support structure210may be starting material205), or the support structure210may be destroyed in the course of processing material205and/or removing a finished part or part component from frame230and/or support structure210, or the support structure210may be a resuable structure that is not incorporated into the part or part component. An exemplary support structure210is 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, non-woven fabrics, or combinations thereof. If support structure210is a material with a low surface energy that might slip against gasket393, gasket390or gasket395(if used), support structure210may 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.

It should be understood that material205is 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. Material205may be pliable. That is, if material205is suspended under its own weight, as in a fabric drape test, the material will not remain within ±35° of a plane.

As shown inFIGS.3A-H, the frame230may have a variety of embedded structures. For example, frame230may comprise one or more ejection pins300. In some aspects, ejection pins300may be present in top frame200or bottom frame220, or both the top frame200and the bottom frame220. As shown, bottom frame220comprises ejection pins300and top frame200does not. Reference numbers360highlight the flat surface of top frame200corresponding to the location of ejection pins300. In this way, applying pressure to the ejection pins300may separate the top frame from the bottom frame, by pushing the top frame away from the bottom frame.

Frame230may further include one or more alignment pins310. Alignment pins310may be present in the top frame200or the bottom frame220, or in a complementary pattern on the top frame200and bottom frame220(to allow mating of the top frame200and bottom frame220). As shown, alignment pins310protrude from an upper surface of bottom frame220, and correspond to holes370in top frame200. This allows a lower surface of top frame200to sit flush against the upper surface of bottom frame220when alignment pins310are aligned with holes370. Holes370may, but do not have to, go completely through the thickness of top frame200. Rather, holes370should be approximately of the same height into top frame200as the height of alignment pins310from the upper surface of bottom frame220. The alignment pins310are 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 frame230, or along the entire perimeter of frame230, or could be irregular and/or asymmetric about a center line (along the x-axis or the y-axis) of the frame230.

Any desired number of alignment pins310could 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 pins310may be used to orient and/or help secure a pliable 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 30 pins, or at least 40 pins, or 46 pins. For some working materials and manufacturing operations, as few as 2 pins might work, or 8 pins, or 12 pins. It may be desirable to place alignment pins310at intervals between 60 mm and 360 mm (inclusive of endpoints) around the perimeter of the frame230. If the intervals are irregular, it may be desirable to place the pins no more than 360 mm 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 structure210, if used. Alternately, support structure210could sit between bottom frame220and top frame200without seating support structure210on an alignment pin, particularly, but not exclusively, if support structure210is uniform throughout the area350within the frame230(e.g., a uniform mesh or grid, a uniform solid surface, etc.). Seating one or more apertures in support structure210on one or more alignment pins310may be more helpful where the support structure210is discontinuous or non-uniformly patterned, making the placement of the support structure210relative to the frame230more important for location determination, as described in further detail below. If the support structure210and/or working material205are seated on the alignment pins310, they may be seated on all of the alignment pins310present on frame230, or may be seated on only a subset of the alignment pins310. If both support structure210and working material205are seated on a subset of alignment pins310, they may be seated on the same subset of alignment pins310, or different subsets of alignment pins310, or overlapping subsets of alignment pins310.

The frame may include magnets320. Magnets320may be of opposite polarity in the top frame200and bottom frame220, and may tend to secure the top frame200to the bottom frame220. 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 frame220to the top frame200. Alternatives to magnets could serve as closures for the frame230, 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 inFIG.3A, frame230may comprise one or more stand-offs305. Stand-offs305may be used to create a fixed distance between top frame200and bottom frame220when the top frame200are in a mated configuration (as shown inFIG.3H). The use of stand-offs305to create a fixed space prevents the material205and/or support structure210from defining the spacing between the frames, giving a consistent frame structure. The distance created by the stand-off could be greater than 0 and less than 1 mm, or between 1 mm and 2 mm (inclusive of endpoints) or greater than 2 mm, depending on the nature of the materials205and/or support structure210being used in the frame. In different manufacturing processes or with different materials, different stand-offs305could be used with what is otherwise the same frame230.

As shown in the exploded view of the top surface of bottom frame220inFIGS.3C and3D, the frame may comprise a gasket395. The gasket is shown on the top surface of bottom frame220, however, the gasket395could be attached to the bottom surface of top frame200, or there could be a gasket395on both the top surface of bottom frame220and the bottom surface of top frame200. The gasket may be compressible, and may serve to help secure a support structure210and/or working material205within the frame. Alternately or additionally, as shown inFIG.3C, the top frame200(or bottom frame220, not shown) may have a groove or indentation380along an outer surface of the frame. A gasket390may be configured to sit in a press-fit configuration within the indentation380, as shown inFIG.3D. A portion of support structure210and/or working material205may wrap at least partially around the outer surface of frame230, and the gasket390may sit over the support structure210and/or working material205within the indentation380, as shown inFIG.3D. Gasket(s)395and/or390may be used to help secure support structure210and/or working material205, and may help to regulate the tension on the working material205during manufacturing operations. A gasket may be particularly useful, but not exclusively useful, for securing working material205where a relatively low number of alignment pins are used, or where working material205may be prone to ripping or unraveling if apertures are made in working material205to accommodate one or more alignment pins310. A gasket may be used to secure the material205, even under tension, if tension is desired, without piercing the material. If desired, material205may be pulled taut or stretched as it is secured in frame230, to tension material205. Some tension in material205may help secure material205in place during manufacturing operations which might otherwise displace material205or portions of material205. For example, some tautness in material205may reduce movement of material205during stitching or other needlework operations. In some embodiments, a single part frame230(i.e., without separate top and bottom frames) may be used with a gasket as shown inFIG.3Dto secure material205and/or support structure210to the frame230, or, alternatively, the bottom frame220may in some instances be used without a top frame200by securing material205and/or support structure210to the bottom frame220using gasket390. The gasket390inFIG.3Dis shown as a solid rod, but could be hollow (e.g., a tube), and could be continuous or discontinuous around the perimeter of the frame230. Any suitable material may be used for gasket390(or gasket395or gasket393) 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 inFIGS.3A and3B, an alignment tab330extends from the bottom frame220. The alignment tab330could extend from the top frame200or the bottom frame220or could be positioned between the frames and secured in place by a gasket395or390, or could be secured in place by a press-fit around one or both of the top frame200and the bottom frame220, or could be otherwise secured to the assembled frame (e.g., by screws, bolts, adhesives, putty, magnets, etc.). The alignment tab330includes at least one alignment element, and, as shown, includes two alignment elements340a,340bon the alignment tab330.

More than one alignment tab330may be used, with each alignment tab330having at least one alignment element. If more than one alignment tab330is used, additional alignment tabs may extend from the same side of the frame (e.g., long side270, opposite long side270a, short side240, opposite short side240a, or corresponding sides of bottom frame220), 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 tabs330may be placed near opposite ends of that side. For example, a first alignment tab on long side270or250may be placed near short side240or260, such as within 200 mm of the short side, or within 150 mm of the short side, or within 100 mm of the short side. A second alignment tab on long side270or250may be placed near short side240aor260a, such as within 200 mm of the short side, or within 150 mm of the short side, or within 100 mm 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 frame230, or may be positioned asymmetrically. 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.

The alignment element may protrude from the alignment tab330. 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 tab330. The alignment element on alignment tab330may be engaged by a securement mechanism on a manufacturing station. For example, as shown inFIG.5, a frame230may have two alignment tabs330a,330b, with alignment elements corresponding to securement mechanisms520a,520bon manufacturing station500. Where the alignment element on alignment tab is a protrusion, the securement mechanism 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 tab330. Where the alignment element on alignment tab330is an aperture or discontinuity, the securement mechanism(s)520a,520b, as shown on manufacturing station500, may be protrusions, such as a pin or rod, sized and positioned to engage the aperture or discontinuity on alignment tab330. Other corresponding securement elements could be used to engage the alignment elements on the alignment tab at 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 frame230may be prepared for use in a manufacturing process as depicted inFIG.4. The frame230could be prepared manually, by a human operator. However, it may be desirable to prepare the frame using an automated process. In this case, frame230may be placed in an assembly/disassembly machine, shown as step410in assembly/disassembly process400. The alignment tab330on frame230may be engaged by a securement mechanism on the assembly/disassembly machine, shown as step420. At step430pins in the assembly/disassembly machine, configured to align with one or more ejection pins300in frame230, may rise to separate top frame200from bottom frame220, e.g., by exceeding the attractive force of magnets320in frame230. 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 step440, the top frame200is removed from the bottom frame220. The top frame200is removed from the bottom frame220in that lower surface of the top frame200is distanced from the bottom frame220. In some circumstances, this distance might just enough to remove or add materials between the top frame200and the bottom frame220. In other circumstances, the top frame200could be moved away from the bottom frame220, or vice versa, or even temporarily removed from the assembly/disassembly machine. At step450, any material205and/or support structure210remaining in the frame from prior manufacturing operations, and which are no longer desired within the frame, may be removed from the frame, including alignment pins310, if the material205and/or support structure210is engaged with the alignment pins310. 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, step450, and potentially steps430and440, may be unnecessary.

At step460, new material205and/or support structure210may be placed in the frame. Placing the material205and/or support structure210in the frame may include seating the material205and/or support structure210on one or more alignment pins310in frame230. If the support structure210from prior manufacturing operations is to be used again, the support structure210may remain in place during the assembly/disassembly processes. If the support structure210is intended to remain in place during assembly/disassembly of the frame, support structure210may have ejection pins or holes corresponding to frame230to facilitate the opening of the frame230, or, alternatively, may have holes or cut-outs (e.g., irregularities in the perimeter of the support structure210) so that the support structure is not present near the ejection pins or holes and does not interfere with opening the frame.

Once new material205and/or support structure210are placed on the frame, the top frame200is mated to the bottom frame220(if a top frame200is used). That is, top frame200may be placed on top of alignment pins310in bottom frame220, or, alternatively, alignment pins310in top frame200may be placed on the bottom frame220. The top frame200may be pressed against the bottom frame220. This pressing may be used to compress any gaskets395, material205, and/or support structure210between the top frame200and the bottom frame220sufficiently to engage the closure system that will hold the top frame200and bottom frame220together during manufacturing operations (e.g., magnets320). In some configurations, it will not be necessary to press the top frame200and bottom frame220together. For example, a magnet or tie-based closure system may pull the frame components together without exerting separate forces on the frame.

The top frame200may fit into bottom frame220using a tongue-and-groove structure, as shown inFIGS.3F-H. As shown, a tongue392, shown on top frame200, fits into a groove394on bottom frame220. However, the tongue could be placed on the bottom frame220and the groove placed on the top frame200. An inner gasket393may be placed within the groove394. When tongue392is placed into groove394over material205and/or support structure210, inner gasket393is compressed, exerting a force that tends to press material205and/or support structure210against the tongue392, holding the material205and/or support structure210in place. The inner gasket393is shown on one side wall of groove394, but could be placed on the opposite sidewall of groove394, or separate gaskets could be placed on each of the sidewalls of groove394. Alternately or additionally, gasket393could be placed at the bottom of the groove394, however, such a gasket may tend to apply an upward force against the tongue392(or a downward force against tongue392, if tongue392is disposed on the bottom frame220), 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 gasket393could be placed on a surface of the tongue392, either side, both sides, bottom, or all three sides of tongue392that are placed in groove394.

If a gasket390around an outer edge of frame230is used, it may be secured to the outer edge at step490. Securing the gasket may involve wrapping portions of material205and/or support structure210around the frame230. As noted above, gasket390could be placed in an indentation380in frame230over the wrapped portions of material205and/or support structure210. Securing gasket390may be in addition to or in lieu of seating the new material205and/or support structure210on alignment pins310at step460.

When the new material205and/or support structure210are secured and the frame230is closed, the assembly/disassembly machine may disengage the alignment tab330. The frame230can be removed, manually or mechanically, from the assembly/disassembly machine.

An assembled frame230ready for manufacturing operations is shown inFIG.5Awith new material205secured in the frame230. A support structure (not shown) may also be present. Alternately, a support structure210may be present with no new material205. For example, the support structure210may be used during additive deposition operations, such as 3D printing, extrusion, spray deposition, etc., such that a material205is not originally present in the frame, but is deposited on the support structure210as part of the manufacturing operations performed with the frame230. Of course, other materials could be placed on support structure210as part of the manufacturing operations, for example, lying textile components on the support structure as part of a manufacturing operation. And additive deposition could be used to add to an original material205.

The assembled frame230is shown inFIGS.5A-Bwith alignment tabs330aand330bon opposing long sides of the frame (e.g., long sides270,270aand/or250,250a). 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 frame230could rotate. In other circumstances, only one alignment tab may be used. The alignment tabs330aand330binteraction with securement mechanisms520aand520bat manufacturing station500. As shown, alignment tabs330aand330bcomprise apertures, and securement mechanisms520aand520bcomprise raised protrusions from a surface of the manufacturing station500that can fit into the apertures on alignment tabs330aand330b. Alternately, alignment tabs330aand330bcould comprise protrusions that fit into apertures on manufacturing station500. Or alignment tabs330aand330band securement mechanisms520aand520bcould 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 tab330acould include a protruding pin, and a second alignment tab330bcould include an aperture. As another example, a first alignment tab330acould include a press-fit mechanism and a second alignment tab330bcould include a screw.

When the alignment tabs330a,330bon frame230are engaged with the securement mechanisms520a,520bat the manufacturing station500, the frame is positioned in a known location and orientation relative to the manufacturing station500, as shown inFIG.5B. Without additional inspection or adjustment, a manufacturing operation can be performed with confidence in the location of the frame230, and, indirectly, in the location of a material205and/or support structure210secured in the frame230. As shown, manufacturing station500comprises a quilting arm510, which could be used for seaming, embroidery, quilting, or other needlework. Such needlework can be positioned on material205with 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 frame230, the position of the work material205, 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 frame230or 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).

FIGS.6A-Edepict how frame230may be used in a series of manufacturing operations. Assembled frame230is engaged with a first manufacturing station600. As shown inFIG.6A, the first manufacturing station600comprises a rotary cutting tool605. Also shown are a second manufacturing station610comprising placement arms615(FIG.6C), and a third manufacturing station500comprising quilting arm510(FIG.6D). 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.

Frame230engages with manufacturing station600using alignment tabs330(shown inFIG.6Aextending from the same side of frame230). The engagement with the alignment tabs confirms that the frame230is in a known and stable position at manufacturing station600. 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 material205inside the frame230. That is, the position of a manufacturing operation can be precisely determined with visually or mechanically determining the position of the material205. The origin used at any particular manufacturing station may be independent of the origin used at other manufacturing stations. Additionally or alternatively, the origin used at a particular manufacturing station for a particular product or product component may be independent of the origin used at that manufacturing station for other products or product components. The origin may be the same for products of product components of the same type (e.g., same specifications for the finished product or product component), or may be determined for each individual product or product component, even between products of the same type.

When the frame230is removed from manufacturing station600, material205has been modified to in-process material650, which in this case has been cut partially (e.g., scored) from material205, as shown inFIG.6B. Frame230with in-process material650may be transferred to a second manufacturing station610, as shown inFIG.6C. The alignment tab or tabs on frame230are then engaged with securement mechanisms at manufacturing station610. As before, manufacturing station610can deduce the positon of in-process material650without direct, visual or mechanical confirmation. When the manufacturing operation at manufacturing station610is complete, manufacturing station610disengages the alignment tabs of frame230, which now secures in-process material660. Frame230is moved to manufacturing station500, where manufacturing station500engages the alignment tab or tabs on frame230, and performs a manufacturing operation, as shown inFIG.6D. In this example, manufacturing station500provides needlework incorporating a layer added to in-process material650at manufacturing station610, resulting in in-process material670. When the manufacturing operation at manufacturing station500is complete, manufacturing station500disengages the alignment tab(s) of frame230, which can then be used to transfer in-process material670to manufacturing station640, as shown inFIG.6E.

Even if the origin point used is different between different manufacturing stations, the manufacturing stations can still perform operations at specified locations. In some instances, a first operation performed at a first manufacturing station, such as placing materials at manufacturing station610at a first location, and a second operation performed at a second manufacturing station, such as the needlework at manufacturing station500, are performed at the same location. The location may be relative to the alignment tab of the frame. Of course, sequential operations could also be placed at different locations, and operations placed at the same location could be separated by other operations placed at different locations.

Manufacturing station640may comprise a further manufacturing operation. Manufacturing station640may comprise a removal and/or inspection station, where a completed product or product component is removed from frame230, possibly by cutting a product or product component away from a portion of the original material205and/or a support structure210. Alternately or additionally, manufacturing station640may comprise an assembly/disassembly machine to remove the product, product component, and/or non-product remnant materials. Manufacturing station640may represent a series of further manufacturing operations, in which each manufacturing station engages the alignment tabs on frame230, performs a manufacturing operation, and disengages the alignment tabs.

FIGS.7A-Bshow how materials may stack up on a manufacturing frame. For example, a support structure210may be used. A first layer710may be pre-cut and placed or cut and placed at a first manufacturing station, as yielded in-process material650. A second layer720may be placed at a second manufacturing station, as yielded in-process material660. A needlework operation at a third manufacturing station may leave stitches730, as yielded in-process material670. As described below, manufacturing may occur on both faces of the frame230and material205, making it possible to have a fourth layer740under support structure210. In this particular example, support structure210may be removable, e.g., by tearing, dissolving, breaking, melting, or subliming support structure210when support structure210is no longer needed. Support structure210may be frangible, sacrificial or dissolvable. Support structure210could also have part lines, gaps, apertures, or the like that would allow the finished part or part component to be removed from the support structure210. Layers710,720,730and740combine to form stack700, as shown inFIG.7B, which in this example was joined together by stitches730.

FIG.8shows an exemplary stack of materials from a top view, where material205is the base material originally layered in the frame prior to manufacturing. As other layers are added, material205remains visible from the top of the stack in areas800aand800b. The stack may include a structural reinforcement layer830, which shows through overlying layers near the center of the product. The stack may include a decorative layer810, which adds color or visual variety to the design of the product. Layer810could 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 frame230as determined from one or more alignment tabs330.

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 material205or support structure210secured within the frame230. A process for manufacturing on both faces of a material is outlined inFIG.9and depicted inFIGS.10A-D. At step910, an assembled frame230is positioned at a first manufacturing station1030. As shown, an up-face1010of the frame (and a corresponding up-face1000of the material205within the frame230) faces up at the first manufacturing station1030(FIGS.10A-B). 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 frame220facing up or the top frame200facing up. The frame230is aligned with the first manufacturing station1030by engagement of the alignment tab(s)330on the frame230at step920. A first manufacturing operation is performed on the first face of the material at step930. 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 station1030.

The frame230can be positioned at a second manufacturing station, shown as step940. At the second manufacturing station, the frame230may be positioned with the up-face1010of the frame up950a(FIG.10D), or with the up-face1010down950b(FIG.10C). As at the first manufacturing station1030, the frame230is aligned with the second manufacturing station by engagement of the alignment tab(s)330on the frame230at step960. A second manufacturing operation is performed on the second face1020of the material at step970. If the up-face1000is facing up, this may involve a manufacturing station1050configured to work from underneath the frame230(FIG.10D). If the up-face1000is facing down, this may involve a manufacturing station1040configured to work on whatever surface is currently facing up (FIG.10C). In either way, the second face1020or down-face of the material can be worked without removing the material205from the frame230. The alignment tab(s)330on the frame230are disengaged, and the frame230can be removed from the second manufacturing station1040or1050. 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.

The methods and equipment described may facilitate manufacturing a variety of products in an agile manufacturing process. Unlike conventional processes, which typically require reconfiguration of equipment to produce different products, the frame and securement mechanisms described above can be used to configure a manufacturing line that can change between different product designs on demand. The manufacturing line could be used efficiently to produce short runs of a few hundred pairs of shoes, or even custom orders of just a single pair of shoes.

As depicted schematically inFIGS.11A-D, a plurality of manufacturing stations1105,1110,1115,1120,1125,1130,1135,1140,1145,1150and1195are provided. In some aspects, as few as two manufacturing stations may be provided, and dozens or hundreds of manufacturing stations may be provided. The plurality of manufacturing stations may be configured to perform two or more different manufacturing operations. For example, the manufacturing stations may perform operations of different types (e.g., cutting, joining, embellishing), or may be configured to perform operations differently (e.g., on a first face of material205, on a second face of material205, at a different angle or using different supplies such as thread or adhesive, etc.). In some aspects, some of the plurality of manufacturing stations perform the same manufacturing operation in the same manner. These duplicative stations could be used, for example, to eliminate processing bottlenecks caused by potentially time consuming processes such as curing, drying, dying, etc., or multi-step operations performed at the same manufacturing station. Each of the plurality of manufacturing stations may comprise a securement mechanism for releasably engaging an alignment tab on a frame.

A plurality of frames, shown separately inFIGS.11A-D, may be provided. Each of the plurality of frames comprises at least one alignment tab. Each of the frames may be configured to support a material or a set of materials. The starting materials1160,1161,1162and1163may be the same or different. For example, starting materials1160,1161,1162and1163could all be undyed canvas. As another example, starting materials1160,1161,1162and1163could be polyester knits of different colors and/or textures. As another example, starting materials1160,1161,1162and1163could each be different, for example, canvas, leather, polyester knit, and mixed-fiber non-woven, respectively.

A first series of manufacturing operations may be performed on a first subset of the starting materials to yield a first set of manufactured products. As shown inFIG.11A, starting material1160may be processed at manufacturing stations1105,1135,1140,1115,1150, and1195, in that order, to produce product1160a. Only a single frame230securing or supporting starting material1160is shown, however, it should be understood that any number of like frames with like starting materials could be processed as part of a first subset of starting materials.

A second series of manufacturing operations is performed on a second subset1161of the set of materials to yield a second set of manufactured products1161a. As shown inFIG.11B, the second series of manufacturing operations may produce a second set of manufactured products1161athat is substantially similar to the first set of manufactured products1160a. As shown inFIGS.11C and11D, the second series or subsequent series of manufacturing operations may produce a second or subsequent set of manufactured products1162a,1163athat is substantially different from the first set of manufactured products in at least one of material content and structure. For example, the manufactured products may have different shapes, different overall material content, different material layers, different needlework or embellishment, different dyes or prints, etc., similar to the differences in shoes100,120,140,160and180inFIG.1. Alternately, or additionally, the manufactured products may have markedly different structures. For example, the manufactured products could represent uppers for different kinds of shoes, such as dress shoes, boots, dance shoes, studio wraps, sneakers, cleats, running shoes, walking shoes, basketball shoes, soccer shoes, golf shoes, tennis shoes, etc.

The different series of manufacturing operations may differ in the order of the operations performed, as seen when comparingFIG.11Awith11B. For example, inFIG.11A, a first operation1165is performed at station1105, a second operation1170is performed at station1135, a third operation1175is performed at station1140, a fourth operation1180is performed at station1115, a fifth operation1185is performed at station1150, and a sixth operation1190is performed at station1195. In contrast, inFIG.11B, a first operation1165ais performed at station1105, a second operation1170ais performed at station1115, a third operation1175ais performed at station1135, a fourth operation1180ais performed at station1140, a fifth operation1185ais performed at station1150, and a sixth operation1190ais performed at station1195. The same manufacturing stations-1105,1115,1135,1140,1150and1195are used in both series—but they are used in a different order.

Different series of manufacturing operations may comprise entirely different subsets of manufacturing operations (disjoint subsets). Different series of manufacturing operations may comprise different but overlapping subsets of manufacturing operations. That is, there may be shared manufacturing operations among different subsets of manufacturing operations. For example, comparingFIGS.11C and11D, the series of operations inFIG.11Cproceeds from a first operation1165bat station1130to a second operation1170bat station111to a third operation1180bat station1145to a fourth operation1190bat station1195, while the series of operations inFIG.11Dproceeds from a first operation1165cat station1125to a second operation1170cat station1150to a third operation1180cat station1195. All of the exemplary subsets of manufacturing operations inFIGS.11A-Dinclude the manufacturing operation performed at manufacturing station1195. An exemplary manufacturing station that may be common to all series of manufacturing operations is a frame assembly/disassembly machine, which may be considered the first and/or last operation in the series. Some or all of the subsets may be disjoint, having no operations or manufacturing stations in common. In this case, the frame assembly/disassembly operations may be performed apart from the manufacturing operations. For example, material205may be provided by a vendor or from an upstream process (not shown) in a frame230. Exemplary upstream processes that might be considered separate from the series of manufacturing operation include extruding or 3D printing a material205within frame230.

Each of the plurality of frames230is shown the same in size and configuration. However, different frames, and/or differently configured frames, could be used. For example, different support structures210within the perimeter of frame230might be used for different series of manufacturing operations and/or for different manufactured products. For example, different products might result from a heat treatment operation depending on whether and what kind of support structure210is used. For example, support structure210might transfer heat readily, hold heat, or resist heat, and could be present or discontinuous in different areas within the perimeter of the frame230. As another example, different frames230among the plurality of frames may have different alignment pin configurations suited to different materials205. For example, materials prone to fraying or unraveling may not contact an alignment pin, whereas materials prone to shifting or stretching might be seated on a relatively high number of alignment pins, and asymmetric patterns of alignment pins might be used with materials having different properties in different orientations (e.g., to make sure the material is oriented in the frame as intended with regard, for example, to a selvage edge, which might or might not be present at the time the material is secured in the frame). The plurality of frames may generally have perimeters of the same dimensions, and/or similarly positioned and oriented alignment tabs.

At each of the plurality of manufacturing stations, the manufacturing operation may comprise aligning the alignment tab(s) on one of the plurality of frames with a securement mechanism(s) on the manufacturing station. The manufacturing operation may include modifying the material on the frame. The nature of the modification can vary (e.g., cutting, joining, embellishing, surface treatments, etc.), and the effect of the modification may vary based on the starting material. For example, polishing TPU yields a different result than polishing leather. When the manufacturing operation is complete, the alignment tab on the frame may be removed or ejected from the securement mechanism on the manufacturing station.

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

Since many possible embodiments may be made within the scope of the invention, this description, including the accompanying drawings, is to be interpreted as illustrative and not in a limiting sense.