MACHINE AND PROCESS FOR ALIGNING ACCESSORY TO MESH STRUCTURE

Abstract

Systems and methods for aligning an accessory with a mesh carpet to provide an improved transition between the components. Various embodiments include the use of one or more alignment points or features on a portion of the mesh carpet to be aligned with an accessory. The alignment features may identify one or more high points on the coil structures comprising the mesh carpet at the portion of the mesh carpet to be aligned with an accessory. Once identified, the alignment features may be used to guide the alignment of the accessory with the mesh carpet.

Description

CROSS-REFERENCE TO RELATED APPLICATION(S)

This application claims the benefit under 35 U.S.C. §119(b) and 37 C.F.R. §1.55 of Chinese Patent for Utility Model No. ZL201520962394.9, filed Sep. 30, 2016 and titled “Machine and Process for Aligning Accessory to Mesh Structure,” the disclosures of which are hereby incorporated herein by reference in their entireties.

FIELD

The disclosure relates generally to a wire mesh construct, and more specifically to a Milanese wire mesh construct having a securement feature aligned to a coil of the mesh.

BACKGROUND

A Milanese mesh construct (also referred to as a “carpet”) is a decorative mesh typically made from a coiled wire with multiple coils threaded together. The threading of the multiple wire coils permits movement between separate coils. The mesh carpet is sometimes used to make necklaces, bracelets and other jewelry or jewelry components.

Various processing steps may be used to improve the overall aesthetics of the mesh. For example, an accessory such as a lug, magnet or other housing, a clip, a folding clasp, a ring, an end piece or end cap, or the like, may be fastened or otherwise affixed to the mesh carpet. Once affixed, the accessory may be soldered to the coil structures at the end of the mesh carpet, thereby rigidly attaching the accessory to at least a portion of the mesh carpet. Typically, however, alignment of the accessory and the mesh is difficult and given little thought. This often results in a visible gap or transition between the accessory and the nearest coil of the mesh. This transition may be mechanically vulnerable to impacts and pressure, and thus may be a common point of failure or breakage.

SUMMARY

Embodiments for aligning an accessory with a mesh carpet to provide an improved transition between the components are described herein. Various embodiments described herein include the use of one or more alignment points or features on a portion of the mesh carpet to be aligned with an accessory. The alignment features may identify one or more high points on the coil structures comprising the mesh carpet at the portion of the mesh carpet to be aligned with an accessory. Once identified, the alignment features may be used to guide the alignment of the accessory with the mesh carpet.

In accordance with various embodiments, a method of aligning an accessory with a mesh carpet may include identifying one or more alignment points on a portion of the mesh carpet formed from a plurality of intertwined coil elements having an upper surface and a lower surface. The alignment points may include one or more points on the upper surface of the coil elements, which define the highest vertical point of each respective coil element. An edge of an accessory may be aligned with the one or more alignment points. In some cases, the accessory may be aligned by determining a first position of the accessory and comparing the first position of the accessory with positions of the one or more alignment points. The accessory may then be moved to a second position that corresponds to the positions of the one or more alignment points. In some embodiments, the accessory may be attached to the mesh carpet at the second position, thereby creating a smooth transition from the accessory to the mesh carpet.

In accordance with an embodiment, a method of making a mesh carpet assembly may include obtaining a mesh carpet that is marked at an uppermost portion of the mesh carpet. A top surface of an accessory may then be aligned with the marked portion and the accessory may be affixed on the mesh carpet. In some cases, the method may further include identifying at least two uppermost points of coil components comprising the mesh carpet, marking each respective uppermost point, and connecting the marked uppermost points to create an alignment line. In some embodiments, the accessory may be aligned by determining the position of the accessory in relation to the alignment line and then positioning the accessory so that the top surface of the accessory aligns with the alignment line. In one example, the uppermost portion of the mesh carpet may be substantially flush with the top surface of the accessory.

In some embodiments, a mesh carpet assembly may include a group of intertwined coils and a region comprising one or more alignment surfaces defined by the uppermost portions of the coils. An accessory may be fastened to the region in an aligned position, thereby creating a transition between the accessory and the mesh carpet. The region comprising one or more alignment surfaces may form a tongue shaped protrusion, and the tongue shaped protrusion may be received within an interior portion of the accessory. The accessory may be a lug, a housing, a clip, a folding clasp, a ring, an end piece, or an end cap. In some cases, the accessory may be soldered to the processed portion.

In some embodiments, the accessory may be a fastener. The fastener may include a tongue shaped protrusion, which may be received within an interior portion of a second accessory. The second accessory may be soldered to the processed portion of the fastener.

Another embodiment may take the form of a device for aligning an accessory with a mesh carpet, comprising: a tension control feature configured to retain a mesh carpet and maintain a tension therein; a camera configured to inspect a position of an accessory disposed on the mesh carpet; a clamp mechanism configured to manipulate a position of a first portion of the mesh carpet that is secured in the clamp mechanism; a processor operatively coupled to the camera and the clamp mechanism, the processor configured to control manipulation of the mesh carpet by the clamp mechanism; and a laser configured to affix the accessory to the mesh carpet once the clamp mechanism has manipulated the mesh carpet into a final position.

BRIEF DESCRIPTION OF THE DRAWINGS

The disclosure will be readily understood by the following detailed description in conjunction with the accompanying drawings, wherein like reference numerals designate like structural elements, and in which:

FIG. 1A depicts a first view of the example prior art strip of mesh affixed to the accessory;

FIG. 1B depicts a second view of the example prior art strip of mesh affixed to the accessory;

FIG. 2A depicts a first view of an example strip of mesh wherein one or more alignment points are identified for aligning an accessory with the mesh;

FIG. 2B depicts a second view of the example strip of mesh wherein one or more alignment points are identified for aligning an accessory with the mesh;

FIG. 3A depicts a first view of an example strip of mesh aligned with an accessory;

FIG. 3B depicts a second view of the example strip of mesh in alignment with the accessory;

FIG. 3C depicts the example strip of mesh in alignment with the accessory along another side of the mesh;

FIG. 4 depicts an example process for affixing a strip of mesh to an accessory in an aligned relationship;

FIG. 5 depicts an example process for creating an alignment line;

FIG. 6 depicts an example process for aligning an accessory with a strip of mesh;

FIG. 7A depicts an exemplary system for aligning an accessory with a strip of mesh;

FIG. 7B depicts an exemplary clamping component of the system of FIG. 7A for aligning an accessory with a strip of mesh;

FIG. 8 depicts an example device having one or more components formed from a mesh material; and

FIG. 9 depicts an example device having a band formed from a mesh material and an accessory for fastening the mesh band.

DETAILED DESCRIPTION

Reference will now be made in detail to representative embodiments illustrated in the accompanying drawings. It should be understood that the following descriptions are not intended to limit the embodiments to one preferred embodiment. To the contrary, it is intended to cover alternatives, modifications, and equivalents as can be included within the spirit and scope of the described embodiments as defined by the appended claims.

Embodiments for aligning and attaching an accessory with a portion of a mesh carpet are described herein. The embodiments may provide a more durable and aesthetically pleasing transition between the components. Various embodiments described herein include the use of one or more alignment points or features on a portion of the mesh carpet as references for aligning the mesh carpet with an accessory (or vice versa). The alignment features may identify one or more high points on the coil structures comprising the mesh carpet at the portion of the mesh carpet to be aligned with an accessory. Once identified, the alignment features may be used to guide the alignment of the accessory with the mesh carpet.

These and other embodiments are discussed below with reference to FIGS. 2A-9. However, those skilled in the art will readily appreciate that the detailed description given herein with respect to these figures is for explanatory purposes only and should not be construed as limiting.

As used herein, a “mesh carpet” or “mesh” may be any structure of associated coils, bands, rings, threads, or the like that, when linked, intertwined or woven, form a continuous structure. For example, a mesh carpet may be a woven fabric, a Milanese mesh, a chain mail mesh, or the like. As further used herein, an “accessory” may be a lug, magnet or other housing, a clip, a folding clasp, a ring, an end piece or end cap, or the like that may be fastened or otherwise affixed to the mesh carpet. The accessory may further serve as a substrate to which another accessory may be affixed.

Certain challenges arise when working with a mesh carpet. Particularly, due to the generally rounded shape of the components (such as the intertwined coils in a Milanese mesh), it can be difficult to align and affix an accessory in a consistent position on each coil along the length of the mesh carpet. In various embodiments, this may be addressed by identifying alignment points on the coils, which may be used to consistently align the accessory with the coils of the mesh carpet.

For example, as depicted in FIGS. 2A and 2B, an alignment line 212 may be determined at one end of the mesh carpet 200. The alignment line 212 may be used to align an accessory and attach it to the end of the mesh carpet 200. An alignment line 212 may be determined at any location on the mesh carpet 200 which is suitable for attachment to an accessory and that satisfies the attachment criteria discussed herein. Further, although the alignment line 212 is shown as a straight line in FIGS. 2A and 2B, the alignment line 212 may be non-linear in various embodiments. A non-linear alignment line may be used if an edge of the accessory being aligned with part of the mesh is non-linear, for example.

The location and criteria may depend on the type of accessory to be attached to the mesh carpet, the mesh carpet's material, the mesh carpet's density of weave, a bond strength between the accessory and mesh carpet, and so on. The accessory may be any manner of bracket, ornament, device, or attachment utilized with any mesh carpet such as a lug, magnet or other housing, a clip, a folding clasp, end pieces, ornament mounts, devices, electronics, magnets or the like.

In one embodiment and as depicted in FIGS. 2A and 2B, marked points 210 on the first coil 202 identify the highest points on the coil structures in the positive Y-direction. Any number of coils 202 may be marked in order to determine the highest point of each coil structure for aligning the mesh carpet with an accessory. In some cases, in a particular location selected for attachment to an accessory (e.g., end portion of the mesh carpet 200 shown in FIGS. 2A and 2B), every coil structure in the selected location may be marked at its highest point. In some embodiments, only selected coil structures within the location may be marked at their respective high points. In some embodiments, the highest point of each coil structure may define an attachment criterion for aligning an accessory, which may be attached to a portion of the mesh carpet. The highest point may be with respect to a top surface of each coil structure. Additionally, the highest point may be relative to a single coil structure since every coil structure comprising a mesh carpet may have the same dimensions and/or height when the mesh carpet is stretched taut. In some embodiments, the attachment criteria may yield a zero or near-zero gap between an edge of the accessory and a coil structure that is nearest that edge. In some cases, an edge of a coil structure may define a point for aligning an accessory with a mesh.

In other embodiments, attachment criteria may include any or all of: a minimum or maximum mechanical bond strength between the accessory and mesh; a dimensional difference between the accessory and mesh (either before or after attachment and any further processing); a size of the accessory and/or mesh; an alignment between a portion of the mesh and an edge (or other part) of the accessory); and so on. Further, although the term “criteria” or “criterion” may be used herein, it should be appreciated that multiple criteria or a single criterion may be used in any embodiment, and so the use of the singular or plural should not be considered a limitation of the disclosure.

As depicted in FIGS. 2A and 2B, the marked points 210 at the highest points of the coil structures may be connected to create an alignment line 212. This connection may be physical or virtual. The alignment line 212 may identify a line for aligning an accessory with the high points of the coil structures of the mesh. The alignment line 212 may connect the marked points 210 of each coil structure, or of select coil structures, of the mesh in order to indicate a line along which an accessory may be attached to the mesh in a position that is aligned with the high points of the coil structures. Further, other parts of a coil structure may be used to create an alignment line 212 in various embodiments.

FIGS. 3A and 3B depict an accessory 302 affixed to the mesh carpet 200 along the alignment line 212. As shown, the accessory 302 is applied to the mesh carpet 200 in alignment with alignment line 212, and thus in alignment with the marked high points of the coil structures forming the mesh carpet 200. As seen in FIG. 3B, as a result of the accessory 302 being positioned in alignment with alignment line 212, it is also aligned with the high points of the coil structures, thereby yielding a zero or near-zero gap between the edge of the accessory 302 and an adjacent coil structure, as viewed from an edge of the mesh carpet 200. A “near-zero” gap may be one that is substantially or actually imperceptible to the unaided human eye; the gap may be substantially imperceptible if it is not apparent upon casual inspection of the mesh carpet. In this manner, a substantially flush or smooth transition between the accessory 302 and the coil structures of the mesh carpet 200 is achieved, as viewed from either or all of the sides, top, and bottom of the mesh carpet 200. (A minor gap is shown in FIG. 3B purely for illustrative purposes; in actuality, the gap may be too small to perceive with the unaided eye.)

As can be appreciated, certain embodiments may determine and utilize an alignment line associated with a surface other than a top or bottom of the mesh carpet. For example, an alignment line or point may be determined on an edge of the mesh carpet instead of on a top or bottom of the mesh carpet.

FIG. 3B shows the transition region in the areas denoted by arrows “C” and “D”. As shown, when the accessory 302 is positioned in alignment with alignment line 212, the transition from the mesh carpet 200 to the accessory 302 is substantially flush (e.g., the gap between the edge of the accessory 302 and the nearest coil structure 202 is near-zero or zero). In particular, the high points of the coil structures 202 in contact with the accessory 302 are substantially flush with the top and bottom surfaces of the accessory 302. This may improve on traditional attachment techniques as the substantially flush transition between the accessory 302 and the nearest coil structure 202 is not only a more aesthetically appealing interface than the transition shown in FIGS. 1A and 1B (denoted by arrows “A” and “B”), but it may be more mechanically stable as well.

In an alternative embodiment shown in FIG. 3C, one or more accessories 302 may be positioned along a different side of the mesh carpet 200 and be in alignment with one or more high points of the coil structures 202 forming the mesh on that side of the mesh carpet 200. In this manner, an alternate attachment of the accessory is possible wherein a transition between the edge of the accessory 302 and the coil structures 202 produces a zero or near-zero gap. Once aligned and installed, an accessory 302 may be affixed to the mesh carpet 200 in accordance with the methods described below with respect to FIG. 4.

FIG. 4 depicts an example process 400 for affixing an accessory to a strip of mesh in an aligned relationship. In order to process a mesh carpet to mate with an accessory, the mesh carpet may be obtained or created, as shown in operation 402. As indicated above, the mesh carpet may be any type of mesh. It may be sourced from any manufacturer of such items. Alternatively, the mesh carpet may be formed locally as part of the process for improving the mesh carpet fit and alignment with various accessories.

In operation 404, an alignment line may be generated along the highest points of the coil structures comprising the mesh carpet. As the various steps herein may be applied to any portion of the entirety of the mesh carpet, the location that the alignment line may be drawn may be identified. For example, as shown in FIGS. 2A and 2B, one portion of the mesh carpet 200 selected for alignment and attachment to an accessory may be an end of the mesh carpet. Additionally or alternatively, a different portion (e.g., an opposite end, a top or bottom portion, or an area associated with a center portion) of the mesh carpet 200 may be selected for alignment and attachment to an accessory. The selected attachment portion may depend on the type of accessory to be attached to the mesh carpet 200. The accessory may be any manner of bracket, ornament, device, or attachment utilized with any mesh carpet such as a folding clasp, end pieces, ornament mounts, devices, electronics, magnets or the like.

Once the location is selected, an alignment line may be generated on the mesh carpet. The alignment line may be generated in any manner. In one example, a camera, or other optical sensor, and laser may locate the highest points of the coil structures of the mesh carpet in the selected location, and mark those points. The highest points of the coil structures may then be “connected” by an alignment line that connects the marked points to each other at the selected location of the mesh carpet.

In operation 406, the accessory may be aligned with the mesh carpet using the alignment line. With the mesh carpet being marked (physically, virtually, or otherwise) with an alignment line that connects the highest points of the coil structures, an accessory may be positioned to align with the alignment line in accordance with operation 406. The accessory may be manipulated in any manner in order to position it in alignment with the generated alignment line on the mesh carpet.

In operation 408, the accessory may be affixed to the mesh carpet. For example, the accessory may be applied to the mesh carpet as described above with respect to FIGS. 3A and 3B. As indicated above, the accessory may be applied such that the transitions of the mesh carpet and the edges of the accessory are substantially flush. Once applied, the accessory may be attached to the mesh carpet using any mechanical attachment, chemical attachment, or other suitable attachment mechanism. In one example, the accessory may be affixed on the mesh carpet using a laser welding or other precision welding technique to fuse portions of the accessory to portions of the mesh carpet. The welded portions may form solid sections of material. In another embodiment, an adhesive or other boding agent may be used to attach the accessory to the mesh carpet.

In some embodiments, the accessory affixed to the mesh carpet may operate as a substrate that may mate with a second accessory such as a magnet, attachment mechanism, housing, or tab. The substrate may be C-shaped in certain embodiments; in others, the substrate may define an interior void space that may accept the mesh. The void space may extend entirely through the substrate or partially therethrough.

The accessory may be configured in a number of other ways, any of which may be suitable to form a mounting substrate for a second accessory. For example, the substrate may be processed to form a tongue feature having a protrusion that may be inserted into a mating groove feature formed into an end of the tab. In some cases, the substrate may then be permanently attached to the tab using, for example, a mechanical fastener inserted into a through hole that extends through both the tongue feature of the substrate and the groove feature of the tab. In some embodiments, a laser welding operation may fuse portions of the tongue feature of the substrate to portions of the groove feature and/or other portions of the tab. In another embodiment, an adhesive or other bonding agent may be used to attach the substrate to the tab.

Additionally or alternatively, the end of the mesh carpet may be processed to form a tongue feature having a protrusion that extends along the length of the end of the mesh carpet. The tongue may be formed, for example, by compressing or forging the mesh carpet into a protrusion shape, or using a machining or cutting process. As with the previous examples, the tongue formed in the mesh carpet may be inserted into a mating groove feature formed into an end of an accessory. In some cases, the formed protrusion may be filled with a brazing or welding material. The formed protrusion and brazing material may form a solid section of material that is substantially free of open space or internal cavities. In some cases, the protrusion may be further machined after filling with a brazing material to form the final shape of the tongue feature. The processing of the mesh carpet that forms a processed portion may be performed any time, in any step, or in any process during aligning the accessory and prior to applying the accessory to the mesh carpet.

In some embodiments, the mesh carpet may then be permanently attached to the accessory using, for example, a mechanical fastener inserted into a through hole that extends through both the tongue feature and the groove feature of the accessory. In some cases, a laser welding operation may fuse portions of the tongue feature to portions of the groove feature or other portions of the accessory. In yet another embodiment, the tongue feature may be fused to the groove feature by heating the braze material and compressing the groove into the tongue of the mesh carpet.

The use of a substrate, or substrates, as a mounting surface for a second accessory may provide several benefits. For example, the substrate(s) may provide a large, substantially stable surface to which the second accessory may be mounted or otherwise affixed, especially in comparison to the mesh carpet. The substrate(s) may maintain a uniform tension in at least part of the mesh, thereby reducing the likelihood that the mesh may kink, crumple or otherwise displace; the additional stability provided to the mesh may in turn enhance a bond between the mesh and the second accessory. The substrate(s) may provide a planar surface to which the second accessory may be mounted or otherwise affixed, thereby simplifying the process and bond therebetween.

FIG. 5 depicts an example process 500 for determining an alignment line with respect to a mesh carpet. As shown in operation 502, a mesh carpet may be obtained or created for generating an alignment line in accordance with the method associated with FIG. 4. As indicated above, the alignment line may be used to align an accessory with the mesh for attachment to a portion of the mesh carpet. As such, after obtaining a mesh carpet, a portion of the mesh carpet may be selected for alignment and attachment to an accessory. In one example, a selected portion of the mesh carpet may be an end of the mesh carpet to permit an accessory to be attached thereto in accordance with process 408 described with respect to FIG. 4. As previously mentioned, a different portion of the mesh carpet may be selected depending on, for example, the specific accessory to be aligned and attached to the mesh.

Once the location is selected, the coil structures forming the mesh carpet in that location may be inspected for their respective high points. In this regard, in operation 504, a high point of the coil structures of the mesh carpet may be identified. For example, as shown in FIGS. 2A and 2B, the coil structures 202 forming an end portion of the mesh carpet are inspected for their respective high points. In the example, the high points of the respective coil structures may be identified as the highest point on the coil structure in the positive Y-direction. In operation 506, once the highest point on each coil structure is identified, the point may be marked with a marker such as alignment point 210. The alignment point may take the form of data stored in the memory of and accessed by a processing unit, rather than a physical “mark” on the structure. In some cases, every coil structure in the selected location may be inspected, and their respective high point identified and marked in order to generate an alignment line that passes through all the coil structures in the location, as further described below. In some embodiments, only selected coil structures within the location may be marked at their respective high points in order to generate an alignment line that represents a general trend in the data of the high points of the coil structures in the selected location.

After the high points of the coil structures are marked in operation 506, the alignment points 210 may be connected to generate an alignment line 212 along the mesh carpet in the selected location. In operation 508, the generated alignment line may connect the marked high points to each other to represent an alignment line for aligning an accessory with the highest points of the coil structures in the selected location of the mesh carpet. As previously mentioned, the alignment line 212 may pass through the marked alignment points 210 of each coil structure, or of selected coil structures of the mesh carpet in order to indicate a line along which an accessory may be attached to the mesh carpet in alignment with the high points of the coil structures.

FIG. 6 depicts an example process 600 for aligning an accessory with a mesh carpet. As shown in operation 602, a mesh carpet having an alignment line connecting high points of the coil structures may be obtained. For example, the mesh carpet may be obtained in accordance with the process 500 described with respect to FIG. 5. As indicated above, the alignment line may serve as an alignment line for aligning an accessory with the highest points of the coil structures in a selected location of the mesh carpet. As such, after obtaining a mesh carpet with an alignment line, an accessory may be aligned and applied to the mesh carpet.

In operation 604, the position of the accessory may be inspected. The accessory may be inspected, and later positioned, in any manner. In one example, a CCD camera and laser alignment device may inspect the position of the accessory in relation to the generated alignment line of the mesh carpet. Based on the determined position of the accessory in relation to the alignment line, the accessory may need to be moved in order to align with the alignment line. In some embodiments, the accessory may be positioned on the mesh carpet, inspected for its position relative to the alignment line of the mesh carpet, and the mesh carpet may be moved in order to align its alignment line with the accessory.

In operation 606, the accessory may be positioned to be in alignment with the alignment line. The alignment line may satisfy an attachment criterion that yields a zero or near-zero gap between an edge of the accessory and the nearest coil structures such that the accessory is “in alignment”. In one embodiment, the alignment device may move the mesh carpet at the portion of the mesh carpet where the accessory is positioned until the accessory aligns with the alignment line of the mesh carpet. In some embodiments, the alignment device may move the accessory until it is aligned with the alignment line of the mesh carpet. In some cases, the alignment device may inspect the position of the accessory in relation to the alignment line after it has been moved, and reposition the mesh or accessory as necessary until the accessory is accurately aligned with the alignment line. In one example, the alignment device may move and reposition the mesh carpet or accessory until the transitions of the mesh carpet and the edges of the accessory are substantially flush, using the alignment line for guidance.

In general, the processes 400, 500, and 600 may be implemented on, for example, the system 700 described below with respect to FIGS. 7A and 7B. Further, a mesh carpet that is processed according to these processes may be used as a band strap on a wearable device in accordance with the examples provided below with respect to FIGS. 8 and 9. The processes can also be used to produce a mesh carpet component used in a variety of other applications, including necklaces, bracelets, other jewelry components, and the like.

While any methods disclosed herein have been described and shown with reference to particular operations performed in a particular order, it will be understood that these operations may be combined, sub-divided, or re-ordered to form equivalent methods without departing from the teachings of the present disclosure. Accordingly, unless specifically indicated herein, the order and grouping of the operations are not a limitation of the present disclosure.

FIG. 7A depicts a schematic representation of an example system 700 that can be used to align an accessory with a mesh carpet in accordance with the embodiments described herein. In particular, the system 700 can be used to align and affix an accessory to a mesh carpet, such as a band strap for a wearable device, in accordance with the processes described above with respect to FIGS. 4-6. In one example, the system 700 can be used to align and affix a fastener at each end of a wire-mesh band for a wearable device. In some embodiments, the fastener may provide an attachment surface for an accessory to attach to the mesh. In this manner, the fastener may provide a greater surface area for affixing (an accessory) than that provided by the unprocessed mesh carpet. The attachment surface may be a rigid structure on an otherwise non-rigid body (e.g., the mesh carpet) that facilitates attachment of an accessory. As such, a stronger bond may be formed between a fastener and an accessory as compared to the mesh carpet and an accessory. In some cases, the fastener may engage a coupling component at one end of the band strap for coupling the band strap to a device, and may engage a magnetic tab at the opposite end of the band strap for securing the device to a user, as described in more detail below with respect to FIGS. 8 and 9.

FIG. 7A depicts various aspects of a system 700 that can be used together or separately to align and affix an accessory to a mesh carpet. In general, the system 700 includes: a mechanism for retaining a wire mesh component 702; a mechanism for manipulating and moving the wire mesh component 702; a mechanism for inspecting an accessory positioned on the wire mesh component 702; and a mechanism for affixing the accessory to the wire mesh component 702. In the present example, the retaining mechanism may include a stand 710 at each end of the wire mesh component 702. Tension control element 712 may be positioned on each stand 710 for retaining the wire mesh component 702 within the system 700. In some cases, the wire mesh component 702 may have a fastener disposed at both ends. The wire mesh component 702 may be positioned within the system 700 such that each end of the wire mesh component 702 is held in place on a respective stand 710 by the corresponding tension control element 712. The tension control element 712 at each end may be tightened in order to retain the wire mesh component 702 within the system 700. This may allow the wire mesh component 702 to be pulled taut so that there are no kinks in the mesh carpet of the wire mesh component 702 (e.g., to induce tension in the wire mesh component 702).

The system 700 may further include a clamp mechanism 714 with opposing clamp elements 716 for retaining and manipulating the wire mesh component 702. As shown in further detail in FIG. 7B, the clamp mechanism 714 may retain and manipulate a portion of the wire mesh component 702 that has a fastener 724 disposed on it. The system 700 may also include a guide 722 for providing additional support to the wire mesh component 702.

As shown in FIG. 7B, the wire mesh component 702 may be positioned within the system such that a portion of the wire mesh component 702 containing the fastener 724 is received in the clamping mechanism 714. The portion of the wire mesh component 702 with the fastener 724 is held between opposing clamp elements 716. As necessary and based on the position of the accessory with respect to the wire mesh component 702, the wire mesh component 702 may be moved in order to align the fastener 724 and wire mesh component 702, as described above. The opposing clamp elements 716 may rotate and/or linearly move the wire mesh component 702 so that it is aligned with the fastener 724.

As shown in FIG. 7A, the system may also include a camera 706, such as a CCD camera. The camera 706 may be operative to determine a position of the fastener 724 on the wire mesh component 702. The camera 706 may also determine the highest point of at least one coil structure of the wire mesh component 702 (in accordance with the operations discussed above) and compare these values in order to achieve alignment of the fastener 724 and the wire mesh component 702. The camera 706 may be positioned above the portion of the wire mesh component 702 containing the fastener 724 in order to view the alignment of the fastener 724 and the wire mesh component 702. The camera 706 may communicate with a processor (e.g., controller 708) in order to determine the current position of the fastener 724 and wire mesh component 702. This may allow the controller 708 to determine an amount in which wire the mesh component 702 should be moved to align the two parts.

In some embodiments, the controller 708 includes a processing unit (e.g., a microcontroller, processor, or the like) and computer memory for storing computer-readable instructions. In some embodiments, firmware or hardware may be used for storing hard-wired instructions. The computer-readable instructions may be executed by the processing unit, causing the system 700 to perform one or more of the processes described herein. The controller 708 may also include an input/output (I/O) for communicating with other elements of the system, including the camera 706 and clamp mechanism 714.

In addition, the system 700 may include a laser 704 for laser-welding or otherwise affixing the fastener 724 to the wire mesh component 702. The laser welding may occur once the various parts are aligned. The laser 704 may be positioned over the portion of the wire mesh component 702 in order to perform the welding/affixing to join the two parts together. Once the laser 704 has affixed the fastener 724 to the wire mesh component 702, the mesh carpet may be laser-cut or otherwise cut at the attachment point of the fastener 724 so that the fastener 724 is exposed at an end of the wire mesh component 702. Stated differently, the fastener 724 may form an end of the wire mesh component 702 that may subsequently be attached to an accessory.

In some embodiments, the camera 706 and laser 704 may include or be mounted to a positioning mechanism that enables the devices to perform their functions across a continuum of positions. This may allow the camera 706 and the laser 704 to be moved and positioned over the portion of the wire mesh component 702 containing the fastener 724. The positioning mechanism may take the form of a gantry positioner, and may include a fixture that is configured to move the camera 706 and laser 704 along one or more axes using motors, actuators, or the like. Additionally, the system 700 may include one or more directing mechanisms for directing the camera 706 view or laser 704 beam onto the wire mesh component 702.

FIG. 8 depicts an example consumer product having one or more components formed from a mesh material. More specifically, FIG. 8 depicts an example wearable device 800 having a single band strap 804 formed from a metallic mesh material. As shown in FIG. 8, the wearable device 800 includes a band strap 804 attached to a body 802 via a coupling joint. In this example, the band strap 804 includes a coupling component 808 disposed at one end of the band strap 804. The coupling component 808 may mechanically engage the coupling joint to attach the band strap 804 to the body 802. For example, the coupling joint may engage the coupling component 808 via a pivoting hinge or pin engagement.

In some embodiments, the coupling component 808 may include one or more separate pieces that form an end of the band strap 804. For example, the coupling component 808 may be a second accessory that is affixed to a first accessory that is, in turn, affixed to the mesh carpet, as described above. In some embodiments, the coupling component 808 may be formed onto, or integrated with, the mesh carpet of the band strap 804, as described in more detail above with respect to FIGS. 2A-6.

As shown in FIG. 8, the wearable device 800 also includes a mechanism that is configured to engage a portion of the band strap 804 to attach the wearable device 800 to a user. In the present example, the band strap 804 includes a magnetic tab 806 disposed at one end of the band strap 804. As shown, the body 802 is attached or integrally formed with a loop 810 that is configured to receive the magnetic tab 806 and at least a portion of the band strap 804. In the present example, the loop 810 includes an aperture 810a having a height and width that is configured to receive the magnetic tab 806. In other embodiments, the loop 810 may be formed from a partially enclosed shape, including, for example, a C-shaped or U-shaped feature. In some embodiments, the loop 810 may be formed as a unitary structure with the body 802. In some embodiments, the loop 810 may be formed as a separate piece that is attached to the body 802.

In general, to attach the wearable device 800 to a user, the body 802 may be placed against the user's wrist and the band strap 804 may be wrapped around the wrist. The magnetic tab 806 and a portion of the band strap 804 may be inserted into the loop 810 and folded back on itself to secure the wearable device 800 to the wrist of the user. In particular, the magnetic tab 806 may be fed through the aperture 810a of the loop 810 and folded back to attach the magnetic tab 806 to a face of the band strap 804. In some cases, the magnetic tab 806 includes at least one magnetic element and a face configured to attach to a portion of the band strap 804 located between a first and second end. The band strap 804 may be tightened around the user's wrist by pulling the band strap 804 through the aperture 810a and attaching the magnetic tab 806 onto the band strap 804 at the desired location. In this way, the magnetic tab 806 provides for an infinitely adjustable band strap 804.

FIG. 9 depicts an example device having a band formed from a mesh carpet, and a loop embodiment with a protective rail. As shown in FIG. 9, the device 900 includes a body 902 and a band 904 that is configured to be attached to a user. In the present embodiment, the band 904 has a first end that is attached to the body 902 and a second end having a tab 906 that is configured to feed through an aperture of a loop 908 and attach to a surface of the band 904. Similar to the previous examples, the band 904 may be pulled through the aperture of the loop 908 to tighten the band 904 around the user's wrist.

In the example depicted in FIG. 9, the loop 908 includes a protective rail 910 that extends around or is disposed about an outer surface of the band 904 when the band 904 is woven through the loop 908. The protective rail 910 may be configured to prevent or reduce the risk of damage to the band 904, for example, such as that caused by a fall and/or impact. In particular, the protective rail 910 is configured to prevent the mesh of the band 904 from becoming bent or kinked at the loop 908, for example if the device 900 is dropped or receives an impact near the loop 908. As shown in FIG. 9, the protective rail 910 is integrally formed as a unitary structure with the loop 908 and the body 902. In other examples, the protective rail 910 may be formed from a separate piece. In the present embodiment, the protective rail 910 extends along both edges and the outer surface of the band 904 to form a fully closed shape around or about the surface of the band 904. However, in other embodiments, the protective rail 910 may be formed as a partially open shape, such as a bar or post.

The wearable devices 800, 900 may be one of a variety of different types of devices including mechanical devices, electromechanical devices, electronic devices, and so on. In some embodiments, the wearable devices 800, 900 may include a mechanical watch. In some embodiments, the wearable devices 800, 900 may include an electronic device such as, for example, a watch, a health monitoring device, a messaging device, a media player, a gaming device, computing device, and/or other electronic device.

While the present disclosure has been described with reference to various embodiments, it will be understood that these embodiments are illustrative and that the scope of the disclosure is not limited to them. Many variations, modifications, additions, and improvements are possible. More generally, embodiments in accordance with the present disclosure have been described in the context of particular embodiments. Functionality may be separated or combined in procedures differently in various embodiments of the disclosure or described with different terminology. These and other variations, modifications, additions, and improvements may fall within the scope of the disclosure as defined in the claims that follow.

The foregoing description, for purposes of explanation, used specific nomenclature to provide a thorough understanding of the described embodiments. However, it will be apparent to one skilled in the art that the specific details are not required in order to practice the described embodiments. Thus, the foregoing descriptions of the specific embodiments described herein are presented for purposes of illustration and description. They are not targeted to be exhaustive or to limit the embodiments to the precise forms disclosed. It will be apparent to one of ordinary skill in the art that many modifications and variations are possible in view of the above teachings.

Claims

1. A mesh carpet assembly, comprising:

an array of interlocking elements, comprising: a first interlocking element; a second interlocking element configured to move relative to the first interlocking element; wherein the first and second interlocking elements define an attachment region at least partially defined by: a highest point on the first interlocking element; and an edge portion of the second interlocking element; and

an accessory affixed to the array of interlocking elements at the attachment region.

2. The mesh carpet assembly of claim 1, wherein a highest point on the second interlocking element is coplanar with the highest point on the first interlocking element.

3. The mesh carpet assembly of claim 2, wherein:

the mesh carpet assembly further comprises an alignment line extending between the highest point on the first interlocking element and the highest point on the second interlocking element; and

the accessory is affixed to the array of interlocking elements along the alignment line.

4. The mesh carpet assembly of claim 1, wherein a highest point on the second interlocking element is positioned within the array of interlocking elements below the highest point on the first interlocking element.

5. The mesh carpet assembly of claim 4, wherein:

the mesh carpet assembly further comprises a non-linear alignment line extending between the highest point on the first interlocking element and the highest point on the second interlocking element; and

the accessory is affixed to the array of interlocking elements along the alignment line.

6. The mesh carpet assembly of claim 1, wherein the second interlocking element is offset from the first interlocking element such that the highest point on the first interlocking element is closer to the accessory than a highest point on the second interlocking element.

7. The mesh carpet assembly of claim 1, wherein the first and the second interlocking elements contact a lateral surface of the accessory to affix the accessory to the array of interlocking elements.

8. The mesh carpet assembly of claim 1, wherein:

the array of interlocking elements further comprises a third interlocking element configured to move relative to the first interlocking element;

the attachment region is further defined by an edge portion of the third interlocking element; and

the first interlocking element is positioned within the array of interlocking elements between the second and third interlocking elements.

9. The mesh carpet assembly of claim 8, wherein the accessory extends between the edge portion of the second interlocking element and the edge portion of the third interlocking element.

10. A method of affixing an accessory to a mesh, comprising:

identifying an alignment point on a portion of the mesh, the alignment point comprising: a highest point on an upper surface of a mesh element;

aligning an edge of the accessory with the alignment point such that part of the mesh is within the accessory; and

affixing the accessory to the portion of the mesh within the accessory.

11. The method of claim 10, wherein the mesh comprises a group of intertwined metal coils.

12. The method of claim 11, wherein a dimension of a gap between the edge of the accessory and an adjacent one of the intertwined metal coils is substantially imperceptible.

13. The method of claim 10, wherein:

the accessory is a first accessory; and

the method further comprises: aligning an edge of a second accessory with the alignment point such that part of the accessory is within the second accessory; and attaching the second accessory to the first accessory.

14. The method of claim 13, wherein the second accessory comprises a coupling component operative to attach the mesh to an electronic device.

15. The method of claim 10, wherein the mesh is a woven fabric.

16. An attachment system for an electronic device, comprising:

a body portion defining a surface of the electronic device and having a coupling feature;

an accessory removeably engaged with the body portion at the coupling feature; and

a mesh carpet assembly comprising an interlaced grouping of wires and affixed to the accessory along an alignment line, the alignment line being defined by uppermost portions of the interlaced grouping of wires.

17. The attachment system of claim 16, wherein the alignment line is non-linear.

18. The attachment system of claim 16, wherein the accessory is at least one of welded or soldered to the mesh carpet assembly along the alignment line.

19. The attachment system of claim 16, wherein the coupling feature comprises at least one of:

a pin;

a strap;

a clasp; and

a tongue shaped protrusion.

20. The attachment system of claim 16, wherein:

the accessory is a first accessory;

the alignment line is a first alignment line; and

the attachment system further comprises a second accessory affixed to the mesh carpet assembly opposite the first accessory and along a second alignment line defined by the uppermost portions of the interlaced grouping of wires.

21. The attachment system of claim 16, wherein each of the interlaced grouping of wires is moveable relative to the mesh carpet assembly.