Non-rigid material multi-frame manufacturing apparatus

Abstract

Aspects hereof relate to a multi-frame manufacturing apparatus for manufacturing articles from non-rigid materials and methods for manufacturing articles utilizing a multi-frame manufacturing apparatus. The multi-frame manufacturing apparatus includes a plurality of discrete frames, each frame including a movement mechanism that enables it to move between sequentially arranged processing stations. Each movement mechanism permits substantially horizontal movement forward and backward. The movement mechanism for at least one of the frames permits substantially vertical movement both up and down. Actuation of the movement mechanisms for at least two frames may permit the frames to switch their relative positions. Each frame additionally includes at least one gripping mechanism for temporarily securing non-rigid material in place on the framed for processing.

What is claimed is: 
     
         1 . A manufacturing tool comprising:
 a first rectangular frame having at least one perimeter sidewall surrounding a first central void; and   a second rectangular frame having at least one perimeter sidewall surrounding a second central void,   wherein two opposing sides of each of the first and second rectangular frames include a gripping mechanism that temporarily grips a non-rigid material and a movement mechanism that permits at least one of horizontal movement and vertical movement between first and second parallel side rails.   
     
     
         2 . The manufacturing tool of  claim 1 , wherein the gripping mechanism is a clamping mechanism that has an open material-receiving position and a closed material-gripping position. 
     
     
         3 . The manufacturing tool of  claim 1 , wherein the non-rigid material includes a stretch direction and a non-stretch direction, and wherein the gripping mechanism grips the non-rigid material along the stretch direction. 
     
     
         4 . The manufacturing tool of  claim 1 , wherein each of the first and second parallel side rails includes a first track and a second track, wherein the movement mechanism of the first rectangular frame is coupled with the first track such that horizontal movement is permitted, and wherein the movement mechanism of the second rectangular frame is coupled with the second track such that horizontal and vertical movement are permitted. 
     
     
         5 . The manufacturing tool of  claim 4 , further comprising at least one linear actuator that causes the horizontal movement of the first rectangular frame and the second rectangular frame. 
     
     
         6 . The manufacturing tool of  claim 5 , further comprising at least one piston that causes the vertical movement of the second rectangular frame. 
     
     
         7 . The manufacturing tool of  claim 6 , wherein the at least one linear actuator and the at least one piston cooperate with one another to permit the first rectangular frame and the second rectangular frame to switch positions. 
     
     
         8 . The manufacturing tool of  claim 1 , further comprising a material loading mechanism that loads the non-rigid material onto one of the first rectangular frame and the second rectangular frame. 
     
     
         9 . A manufacturing tool comprising:
 a first frame having a first pair of sidewalls positioned opposite one another and a second pair of sidewalls positioned opposite one another and perpendicular to the first pair of sidewalls to form a first rectangular structure;   a second frame having a first pair of sidewalls positioned opposite one another and a second pair of sidewalls positioned opposite one another and perpendicular to the first pair of sidewalls to form a second rectangular structure; and   first and second parallel side rails spaced apart from one another at a distance sufficient for the first and second frames to be movably positioned between the first and second parallel side rails;   wherein the first frame and the second frame are movably positioned between the first and second parallel sidewalls such that substantially horizontal movement is permitted forward and backward,   wherein at least one of the first frame and the second frame is movably positioned between the first and second parallel sidewalls such that substantially vertical movement is permitted up and down,   and wherein each sidewall of the first pair of sidewalls of the first frame and each sidewall of the first pair of sidewalls of the second frame includes a gripping mechanism for temporarily gripping a non-rigid material.   
     
     
         10 . The manufacturing tool of  claim 9 , wherein the gripping mechanisms of each of the first pair of sidewalls of the first frame and the first pair of sidewalls of the second frame is a clamping mechanism that has an open material-receiving position and a closed material-gripping position. 
     
     
         11 . The manufacturing tool of  claim 9 , wherein the non-rigid material includes a stretch direction and a non-stretch direction, and wherein the gripping mechanism grips the non-rigid material along the stretch direction. 
     
     
         12 . The manufacturing tool of  claim 9 , wherein each of the first and second parallel side rails includes a first track and a second track, and wherein each sidewall of the first pair of sidewalls of the first frame includes a first movement mechanism coupled with the first track of each of the first and second parallel side rails such that horizontal movement is permitted, and wherein each sidewall of the first pair of sidewalls of the second frame includes a second movement mechanism coupled with the second track of each of the first and second parallel side rails such that horizontal and vertical movement are permitted. 
     
     
         13 . The manufacturing tool of  claim 9 , further comprising at least one linear actuator that causes substantially horizontal movement of the first frame and the second frame. 
     
     
         14 . The manufacturing tool of  claim 13 , further comprising at least one piston that causes substantially vertical movement of the at least one of the first frame and the second frame. 
     
     
         15 . The manufacturing tool of  claim 14 , wherein the at least one linear actuator and the at least one piston cooperate with one another to permit the first frame and the second frame to switch positions. 
     
     
         16 . The manufacturing tool of  claim 9 , further comprising a material loading mechanism that loads the non-rigid material onto one of the first frame and the second frame. 
     
     
         17 . A method of manufacture utilizing a multi-frame manufacturing apparatus, comprising:
 loading a non-rigid material onto a first rectangular frame at a loading station, the first rectangular frame having opposing sides that each include a gripping mechanism and a first movement mechanism;   causing the gripping mechanisms to temporarily grip the non-rigid material onto the first rectangular frame;   causing the first movement mechanism to move the first rectangular frame substantially horizontally in a first direction while synchronously causing a second movement mechanism associated with a second rectangular frame to move substantially horizontally in an opposing direction and substantially vertically such that the second rectangular frame and the first rectangular frame change positions.   
     
     
         18 . The method of  claim 17 , wherein the gripping mechanism is a clamping mechanism that has an open material-receiving position and a closed material-gripping position. 
     
     
         19 . The method of  claim 17 , wherein the non-rigid material includes a stretch direction and a non-stretch direction, and wherein the gripping mechanisms grip the non-rigid material along the stretch direction. 
     
     
         20 . The method of  claim 17 , wherein the first movement mechanism comprises at least one linear actuator that causes the horizontal movement of the first rectangular frame, and wherein the second movement mechanism comprises at least one linear actuator that cause the horizontal movement of the second rectangular frame and at least one piston that causes the vertical movement of the second rectangular frame.