U.S. patent application number 10/096690 was filed with the patent office on 2002-08-22 for apparatus and process for producing high quality metallic fiber mesh.
Invention is credited to Liberman, Michael, Quick, Nathaniel R..
Application Number | 20020112334 10/096690 |
Document ID | / |
Family ID | 23031019 |
Filed Date | 2002-08-22 |
United States Patent
Application |
20020112334 |
Kind Code |
A1 |
Quick, Nathaniel R. ; et
al. |
August 22, 2002 |
Apparatus and process for producing high quality metallic fiber
mesh
Abstract
The process for making fine metallic mesh is disclosed
comprising the steps of cladding an array of metallic wires with an
array cladding material to provide an array cladding. The array
cladding is drawn for reducing the diameter thereof and for
reducing the corresponding diameters of each of the metallic wires
for producing a clad array of fine metallic fibers within the array
cladding. The array cladding is fashioned into a mesh by weaving,
braiding, crocheting and the like thereby forming a series of bends
in the clad array for reducing interaction between adjacent
portions of the array cladding. The array cladding material is
removed for producing fine metallic mesh from the array of the fine
metallic fibers.
Inventors: |
Quick, Nathaniel R.; (Lake
Mary, FL) ; Liberman, Michael; (Deland, FL) |
Correspondence
Address: |
KNOBBE MARTENS OLSON & BEAR LLP
620 NEWPORT CENTER DRIVE
SIXTEENTH FLOOR
NEWPORT BEACH
CA
92660
US
|
Family ID: |
23031019 |
Appl. No.: |
10/096690 |
Filed: |
March 12, 2002 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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10096690 |
Mar 12, 2002 |
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09950466 |
Sep 10, 2001 |
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6381826 |
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60270360 |
Feb 21, 2001 |
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Current U.S.
Class: |
29/419.1 |
Current CPC
Class: |
Y10T 29/4981 20150115;
Y10T 29/49801 20150115; D04C 1/02 20130101; B21C 37/047 20130101;
B60C 9/0007 20130101; Y10T 29/49812 20150115 |
Class at
Publication: |
29/419.1 |
International
Class: |
B23P 017/00 |
Claims
What is claimed is:
1. A process for making fine metallic mesh, comprising: cladding an
array of metallic wires with an array cladding material to provide
an array cladding; drawing the array cladding for reducing the
diameter thereof and for reducing the corresponding diameters of
each of the metallic wires of the array within the array cladding
for providing a drawn array cladding of fine metallic fibers;
forming the drawn array of fine metallic fibers into a metallic
mesh; and removing the array cladding material for producing the
fine metallic mesh from the array of fine metallic fibers.
2. The process for making fine metallic mesh of claim 1, wherein
the act of cladding the array of metallic wires comprises: cladding
a wire with a wire cladding material to provide a wire cladding;
assembling an array of the wire claddings; and cladding the
assembled array of wire claddings with the array cladding material
to provide an array cladding.
3. The process for making fine metallic mesh of claim 2, wherein
the act of cladding the wire with a wire cladding material
comprises electroplating the wire with the wire cladding material
to provide the wire cladding.
4. The process for making fine metallic mesh of claim 1, wherein
the act of drawing the array cladding comprises multiple drawing
and annealing process for producing a drawn array cladding of fine
metallic fibers.
5. The process for making fine metallic mesh of claim 1, wherein
the act of forming the drawn array into a metallic mesh comprises
forming a series of bends along a length of the drawn array
cladding.
6. A fine metallic mesh made from a process comprising: cladding an
array of metallic wires with an array cladding material to provide
an array cladding; drawing the array cladding for reducing the
diameter thereof and for reducing the corresponding diameters of
each of the metallic wires of the array within the array cladding
for providing a drawn array cladding of fine metallic fibers;
forming the drawn array of fine metallic fibers into a metallic
mesh; and removing the array cladding material for producing the
fine metallic mesh from the array of fine metallic fibers.
7. The mesh of claim 6, wherein the act of cladding the array of
metallic wires comprises: cladding a wire with a wire cladding
material to provide a wire cladding; assembling an array of the
wire claddings; and cladding the assembled array of wire claddings
with the array cladding material to provide an array cladding.
8. The mesh of claim 6, wherein the act of cladding the wire with a
wire cladding material comprises electroplating the wire with the
wire cladding material to provide the wire cladding.
9. The mesh of claim 6, wherein the act of drawing the array
cladding comprises multiple drawing and annealing process for
producing a drawn array cladding of fine metallic fibers.
10. The mesh of claim 6, wherein the act of forming the drawn array
into a metallic mesh comprises forming a series of bends along a
length of the drawn array cladding.
11. The mesh of claim 6, wherein the metallic wire is made from
stainless steel.
12. The mesh of claim 6, wherein the metallic wire is made from
nickel.
13. The mesh of claim 6, wherein between 150 and 3,000 of the wire
claddings are assembled into the array.
14. A fine metallic mesh made from a process comprising: cladding a
wire with a wire cladding material to provide a wire cladding;
assembling an array of the wire claddings; and cladding the
assembled array of wire claddings with the array cladding material
to provide an array cladding. drawing the array cladding for
reducing the diameter thereof and for reducing the corresponding
diameters of each of the metallic wires of the array within the
array cladding for providing a drawn array cladding of fine
metallic fibers; forming the drawn array of fine metallic fibers
into a metallic mesh thereby creating a series of bends in the
drawn array cladding for reducing interaction between adjacent
portions of the array cladding; and removing the array cladding
material for producing the fine metallic mesh from the array of
fine metallic fibers.
15. The mesh of claim 14, wherein the act of cladding the wire with
a wire cladding material comprises electroplating the wire with the
wire cladding material to provide the wire cladding.
16. The mesh of claim 14, wherein the act of drawing the array
cladding comprises multiple drawing and annealing process for
producing a drawn array cladding of fine metallic fibers.
17. A metallic mesh comprising a plurality of warps interleaved
with a plurality of weaves, wherein the plurality of warps and
weaves comprise clad metallic threads, and wherein each metallic
thread comprises a plurality of clad fine metal fibers, wherein the
warps have a plurality of bends extending along a longitudinal
length of each of the plurality of warps, and wherein the weaves
have a plurality of bends extending along a longitudinal length of
each of the plurality of weaves, and wherein the warps and weaves
are interleaved so as to create a space between adjacent warps and
a space between adjacent weaves.
18. The metallic mesh of claim 17, wherein the metal fibers are
made of stainless steel.
19. The metallic mesh of claim 17, wherein the metal fibers are
made of nickel.
20. The metallic mesh of claim 17, wherein between 150 and 3,000
metal fibers are assembled into each metallic thread.
21. The metallic mesh of claim 17, wherein each of the weaves makes
perpendicular contact with at least one of the warps.
22. A metallic mesh comprising a plurality of warps interleaved
with a plurality of weaves, wherein the plurality of warps and
weaves comprise metallic threads, and wherein each metallic thread
comprises between 150 and 3,000 fine metal fibers, wherein the
warps have a plurality of bends extending along a longitudinal
length of each of the plurality of warps, and wherein the weaves
have a plurality of bends extending along a longitudinal length of
each of the plurality of weaves.
23. The metallic mesh of claim 22, wherein the metal fibers are
made of stainless steel.
24. The metallic mesh of claim 22, wherein the metal fibers are
made of nickel.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims benefit of U.S. Patent Provisional
application serial No. 60/270,360 filed Feb. 21, 2001. All subject
matter set forth in provisional application serial No. 60/270,360
is hereby incorporated by reference into the present application as
if fully set forth herein.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] This invention relates to metallic tow or metallic threads
and more particularly to an apparatus and method of producing high
quality metallic mesh from an array of metallic threads made from
fine metallic fibers.
[0004] 2. Description of the Related Art
[0005] This invention relates to metallic mesh or metallic fiber
cord and more particularly to an improved apparatus and method of
producing high quality metallic mesh or metallic fabric from an
array of fine metallic fibers. Metallic mesh is generally formed
from a matrix of metallic fiber tow or continuous metallic cord.
The metallic fiber tow or continuous metallic cord is characterized
as an array of parallel metallic fibers forming a continuous cord
of a suitable length. Typically, each of the metallic fibers of the
mesh is less than 50 microns in diameter. The metallic fiber tow
normally includes continuous metallic fibers in a quantity greater
than 19 parallel metallic fibers.
[0006] The production of high quality metallic fiber tow is a more
difficult task than the production of high quality chopped metallic
fibers. Typically, chopped metallic fibers have a length of less
than 2 to 3 centimeters. Both metallic fiber tow and metallic
chopped fibers are formed in a similar manner. The metallic fibers
are formed by cladding an array of metallic wires and drawing the
clad array to reduce the outer diameter thereof and to reduce the
corresponding diameters of the array of metallic wires thereby
producing an array of metallic fibers. The clad array of metallic
fibers is chopped into cladding sections of less than two to three
centimeters. The chopped cladding sections are placed into a
leaching bath to remove the cladding material thereby producing
chopped metallic fibers.
[0007] The metallic fiber tow is a more difficult task to produce
than chopped metallic fibers since clad metallic fiber tow is more
difficult to leach than chopped clad metallic fibers. The metallic
fiber tow is made in a similar fashion with the exception that the
continuous cladding of continuous metallic fibers must be leached
as a continuous cladding of metallic fiber tow. The prior art has
utilized two methods of leaching the continuous cladding of
metallic fiber tow, namely the continuous leaching process and the
batch leaching process. In the continuous leaching process, the
continuous cladding of metallic fiber tow is passed through a
longitudinally extending leaching bath thereby giving a chemical
agent sufficient time to remove the cladding material leaving the
continuous metallic fiber tow. This process necessitated the use of
a long leaching bath, which was unsatisfactory in many cases.
Secondly, the continuous cladding of metallic fiber tow had to be
pulled through the longitudinally extending leaching tank thereby
placing substantial stress on the metallic fiber tow after removal
of the cladding material. This substantial stress on the metallic
fiber tow resulted in breakage of some of the metallic fibers in
the metallic fiber tow thereby reducing the quality thereof.
[0008] The second method of leaching the continuous cladding of
metallic fiber tow was through a batch process. In the batch
process, the continuous cladding of metallic fiber tow was reeled
onto a leaching spool and placed in a leaching bath. In order to
prevent the individual metallic fibers of one winding of the
metallic fiber tow from being entangled with individual metallic
fibers of an adjacent winding the continuous cladding of metallic
fiber tow was twisted as the continuous cladding of metallic fiber
tow was reeled onto the leaching spool.
[0009] After the batch leaching process, the continuous cladding of
metallic fiber tow was unreeled from the leaching spool and placed
on a transport spool or for ultimate use. Unfortunately, the
twisting of the continuous metallic fiber tow did not totally
prevent the individual metallic fibers of one winding of the
metallic fiber tow from being entangled with individual metallic
fibers of an adjacent winding of the continuous metallic fiber tow.
Accordingly, the unreeling of the continuous metallic fiber tow
from the leaching spool resulted in breakage of some of the
individual metallic fibers thereby providing poor quality fiber
tow.
[0010] In some instances, the continuous metallic fiber tow was
used in the production of high quality metallic mesh. Many
processes have been known in the prior art for the manufacture and
production of high quality metallic mesh. Among the prior art that
have attempted to provide for the manufacturing and production of
high quality metallic fiber tow and/or high quality metallic mesh
are the following United States Patents.
[0011] U.S. Pat. No. 2,050,298 to Everett discloses a process for
the production of stranded wire by reduction from elements of
comparatively large cross-sections. The process comprises the steps
of assembling of a plurality of the elements in side-by-side
relationship. The encased assembly of elements is reduced thus
formed as a unit and imparting a permanent helical twist to the
reduced bundle and then removing the casing.
[0012] U.S. Pat. No. 3,505,039 to Roberts et al. discloses a
product defined as fine metal filaments, such as filaments of under
approximately 15 microns diameter, in long lengths wherein a
plurality of sheathed elements are first constricted to form a
reduced diameter billet by means of hot forming. After the hot
forming constriction, the billet is then drawn to the final size
wherein the filaments have the desired final small diameter. The
material surrounding the filaments is then removed by suitable
means leaving the filaments in the form of a tow.
[0013] U.S. Pat. No. 3,540,114 to Roberts et al. discloses a method
of forming fine filaments formed of a material such as metal by
multiple end drawing a plurality of elongated elements having
thereon a thin film of lubricant material. The plurality of
elements may be bundled in a tubular sheath formed of drawable
material. The lubricant may be applied to the individual elements
prior to the bundling thereof and may be provided by applying the
lubricant to the elements while they are being individually drawn
through a coating mechanism such as a drawing die. The lubricant
comprises a material capable of forming a film having a high
tenacity characteristic whereby the film is maintained under the
extreme pressure conditions of drawing process. Upon completion of
the constricting operation, the tubular sheath is removed. If
desired, the lubricant may be also removed from the resultant
filaments.
[0014] U.S. Pat. No. 3,698,863 to Roberts et al. discloses a
metallic filament that has an effective diameter of less than 50
microns and is formed while surrounded by a subsequently removed
sacrificial matrix. The filament has a preselected peripheral
surface varying from substantially smooth to re-entrant and a
preselected surface to volume ratio. The area of the filament also
has a controlled non-uniformity along the length thereof which
provides an acceptable dimensional tolerance. The metallic filament
may be substantially one metal, bimetallic or tubular.
[0015] U.S. Pat. No. 3,977,069 to Domaingue, Jr. discloses that
this invention contemplates a method and apparatus for taking fine
metal fibers having a diameter range from 0.5 microns to
approximately 150 microns and cutting the fibers into precise short
lengths. The method and apparatus comprises first moistening tows
of metal fibers and unwinding the tows from spools and positioning
them into tow bands. A stiffened ribbon made from the tow bands is
cut to the desired precise lengths in order to prevent cold welding
or deformation of the ends of the fibers during the cutting
operation. Materials that may be used for stiffening the fibers
include starch, PCA, ice, etc.
[0016] U.S. Pat. No. 3,977,070 to Schildbach discloses the method
of forming a tow of filaments wherein a bundle of elongated
elements such as rods or wires, is clad by forming a sheath of
material different from that of the elements about the bundle. The
bundle is subsequently drawn to constrict the elements to a desired
small diameter. The elements may be formed of metal. The bundle may
be annealed, or stress relived, between drawing steps as desired.
The sheath may be formed of metal and may have juxtaposed edges
thereof welded together to retain the assembly. The sheath is
removed from the final constricted bundle to free the filaments in
the form of tow.
[0017] U.S. Pat. No. 4,010,004 to Brown et al. discloses a metallic
velvet material comprising a woven textile pile fabric wherein at
least a portion of the woven base fabric and/or the velvet
surface-forming pile yarns is metallic. The metallic yarn may
comprise a blended yarn formed of staple metal fibers and
conventional nonmetallic textile fibers, or may be formed of
continuous metal filament material. The metal fibers, or filaments,
are preferably formed with rough unmachined and unburnished,
fracture-free outer surfaces for improved retention in the velvet
pile fabric.
[0018] U.S. Pat. No. 4,109,709 to Honda et al. discloses heat pipes
comprising an outer tubular material closed at both ends. A wick of
metal fibers covering an inner tubular material is inserted in the
outer tubular material. A heat transfer volatile liquid is confined
in the closed outer tubular material. An evaporation region and a
condensing region are respectively constituted in the end portions
of the outer tubular material. The liquid in the evaporation region
vaporizes when heated and the vapor is passed to the condensing
region to condense while giving the heat of the vapor to other
materials outside the heat pipe. The condensed liquid is returned
to the evaporation region by the capillary action of the wick, thus
repeating a cycle of the evaporation and condensation.
[0019] U.S. Pat. No. 4,118,845 to Schildbach discloses the method
of forming a tow of filaments and the tow wherein a bundle of
elongated elements such as rods or wires is clad by forming a
sheath of material different from that of the elements about the
bundle. The bundle is subsequently drawn to constrict the elements
to a desired small diameter. The elements may be formed of metal.
The bundle may be annealed, or stress relieved, between drawing
steps as desired. The sheath may be formed of metal and may have
juxtaposed edges thereof welded together to retain the assembly.
The sheath is removed from the final constricted bundle to free the
filaments in the form of tow.
[0020] U.S. Pat. No. 4,412,474 to Hara discloses a fiber cord
comprising a core that is formed by braiding a plurality of
strands, each comprising at least one fiber filament of high
elongation. An outer layer element is formed around the core by
braiding a plurality of strands, each comprising at least one fiber
filament of low elongation and high strength. A protective layer
element is formed around the outer layer element by braiding a
plurality of strands, each comprising at least one fiber of high
elongation.
[0021] U.S. Pat. No. 4,514,880 to Vaughn discloses a method and
machine for forming nonwoven batts containing refractory fibers
such as carbon, glass, ceramic or metallic fibers, includes a
conveying table provided with scalloped rollers which separate tows
of filaments and spread the filaments on a conveying table. A feed
roller holds the filaments on the table so that they are conveyed
to a rotating lickerin. The lickerin is provided with teeth that
grasp the filaments so that a tensile force is applied thereto,
thereby breaking the filaments at structurally weak points in the
filaments. The fibers are mixed with textile fibers and transferred
to a foraminous condenser by blowing the fibers through a duct. The
fibers are arranged on the conveyor in a random fashion to form a
batt.
[0022] U.S. Pat. No. 4,610,926 to Tezuka discloses a reinforcing
steel fiber to be mixed in concrete having a shaft portion that has
strength as a mother material. There are on both sides of the shaft
portion, alternately formed knots expanding in width become
increased in width in the direction towards the ends of the fiber
while they become decreased in thickness while knots expanding in
thickness extend almost uniformly over the full length.
[0023] U.S. Pat. No. 4,677,818 to Honda, deceased et al. discloses
a composite rope obtained by a process comprising (1) impregnating
a fiber core of a reinforcing fiber bundle with a thermosetting
resin, (2) coating the outer periphery of the resin-impregnated
fiber core with fibers, and (3) curing the thermosetting resin with
heat.
[0024] U.S. Pat. No. 4,771,596 to Klein discloses a fine
heterogeneous hybrid spun yarn blended from electrostatically
conductive staple fibers and electrostatically non-conductive
staple fibers so that the yarn is electrostatically conductive only
over short discrete lengths. When used in pile fabrics, such as
carpets, the fine yarn is introduced with at least some of the
carpet facing yarns during the carpet making operations. The
resultant carpet structure substantially eliminates electrostatic
shock to a human walking across the carpet and approaching a ground
such as a light switch, radio and another person. Such a carpet
does not constitute a dangerous floor covering. The unique
heterogeneous hybrid spun blended yarn is achieved by process
techniques completely contrary to accepted blending practices.
[0025] U.S. Pat. No. 5,525,423 to Liberman et al. discloses an
apparatus and method for an improved fabric having plural diameter
metallic wires, comprising the drawing of a first cladded metallic
wire to provide a first drawn cladding of reduced diameter. The
first cladding is separated into a primary portion and a secondary
with the secondary portion being drawn to reduce the diameter. A
selected mixture of the primary and the secondary portions are
cladded to provide a third cladding of reduced diameter. The third
cladding is drawn and the claddings are removed to provide a fabric
comprising metallic wires having a major diameter and a minor
diameter. The fabric may be severed into uniform length to provide
slivers of metallic wires having plural diameters. The plural
diameter slivers may be used for various purposes including a
filter medium or may be encapsulated within polymeric material for
providing an electrically conductive metallic layer therein.
[0026] U.S. Pat. No. 5,584,109 to DiGiovanni et al. discloses an
improved battery plate and method of making for an electric storage
battery. The battery plate comprises a plurality of metallic fibers
of a single or plural diameters randomly oriented and sintered to
provide a conductive battery plate with a multiplicity of pores
defined therein. The metallic fibers are formed by cladding and
drawing a plurality of metallic wires to provide the fabric. The
fabric is severed and the cladding is removed to form metallic
fibers. The metallic fibers are arranged into a web and sintered to
form the battery plate.
[0027] U.S. Pat. No. 5,630,700 to Olsen et al. discloses a turbine
nozzle including outer and inner bands having respective mounting
therein. A plurality of vanes extends through respective pairs of
outer and inner holes in the bands. The vane outer and inner ends
are resiliently supported to the bands to allow differential
thermal movement therebetween so that the individual vanes float
relative to the outer and inner bands to prevent thermal stress
failure thereof.
[0028] U.S. Pat. No. 5,707,467 to Matsumaru et al. discloses a high
elongation compact helical steel cord with a high degree of
elongation at break of not less than 5% has a (1xn) structure. The
steel cord comprises three or more base wires which are helically
preformed at a predetermined pitch and that are twisted in the same
direction and at the same pitch so that the ratio P/D of the cord
diameter D to the twisting pitch P is in the range of 8-15 with the
base wire preforming pitch being shorter than the cord twisting
pitch. The finished cord has a helical composite structure with its
elongation under a load of 35 kgf/mm.sup.2 being 0.71%-1.00% and
that under a load of 70 kgf/mm.sup.2 being 1.18%-1.57%. A radial
tire is reinforced with the steel cord preferably as a steel belt
cord. An apparatus for making the steel cord is provided with
revolving preformers on the wire introducing portion of a bunching
machine such that the bunching machine is rotated in a direction
reverse to the rotational direction of the revolving
preformers.
[0029] U.S. Pat. No. 5,722,226 to Matsumaru discloses a steel cord
effective for reinforcing a super-large off-road tire wherein
strands made by simultaneously twisting together 3 to 6 steel wires
in the same twisting direction with the same pitch length. Each of
the steel wires consulting the strands continuously has a small
wavy pattern of a pitch length smaller than the lay length of the
strands and therefore each of the strands has a compound pattern
comprising a wavy pattern formed by the twisting. The small wavy
pattern and gap is formed between steel wires each of the strands
by the small wavy pattern. The lay length P.sub.1 of the strands is
defined by the small wavy pattern. The lay length P.sub.1 of the
steel cord is 8 to 15 times the steel cord diameter D and the
elongation on breakage by tension of the steel cord is over 5%.
[0030] U.S. Pat. No. 5,802,830 to Kawatani discloses that the
present invention relates to a steel cord comprising two core wires
and five outer wires each having a diameter larger than that of
each core wire and integrally twisted on the core wires, wherein a
strand constituted by the five outer wires and the two core wires
has an oblong cross-section.
[0031] U.S. Pat. No. 5,839,264 to Uchio discloses that the steel
cord for reinforcement of an off-road tire has a superior
resistance to penetration and durability with respect to sharp
objects. It has a 3.times.3, a 3.times.4, a 4.times.3 or a
4.times.4 structure, an identical cord diameter at all points along
the steel cord in a longitudinal direction, a cord lay length equal
to from 3.5 to 7.5 times the cord diameter and an elongation at
break of at least 4%. The steel cord is made up of element wires,
each having a wire diameter of from 0.3 to 0.5 mm and a tensile
strength of from 2000 to 3300 Mpa.
[0032] U.S. Pat. No. 5,888,321 to Kazama et al. discloses steel
wire for making steel cord used in rubber product reinforcement has
a tensile strength, Y in N/mm.sup.2, such that
Y.quadrature.-1960d+3920, wherein d is the wire diameter in mm, and
also a flat Vickers hardness distribution in a cross-section
perpendicular to a length direction thereof from the surface to the
interior, but excluding a central portion having a central portion
diameter corresponding to 1/4 of the wire diameter. The steel wire
is made by a method including wet drawing a carbon steel wire rod
material containing 0.80 to 0.89% by weight carbon to a
predetermined intermediate diameter and subsequently heat-treating
and plating to form a final raw material and then wet drawing the
final raw material to form the steel wire. The wet drawing steps
are performed with drawing dies, each of which is provided with a
drawing hole having a drawing hole diameter d.sub.1 and the drawing
die has an approach angle 2.quadrature. equal to from
8.sup..quadrature. to 10.sup..quadrature. and a bearing length of
0.3d.sub.1. The wet drawing of the final raw material includes a
final drawing step performed with a double die and the steel wire
immediately after passing through the final drawing die has its
temperature controlled so as to be less than 150.sup..quadrature.
C.
[0033] U.S. Pat. No. 5,890,272 to Liberman et al. discloses a
process for making fine metallic fibers comprising coating a
plurality of metallic wires with a coating material. The plurality
of metallic wires are jacketed with a tube for providing a
cladding. The cladding is drawn for reducing the outer diameter
thereof. The cladding is removed to provide a remainder comprising
the coating material with the plurality of metallic wires contained
therein. The remainder is drawn for reducing the diameter thereof
and for reducing the corresponding diameter of the plurality of
metallic wires contained therein. The coating material is removed
for providing the plurality of fine metallic fibers.
[0034] U.S. Pat. No. 5,956,935 to Katayama et al. discloses that
the steel wire is made using a carbon steel wire rod material
containing 0.70 to 0.75 wt % carbon and has the characteristics
that its diameter is 0.10 to 0.40 mm and Y.quadrature.-1960d+3580
[Y: tensile strength (N/mm.sup.2), d: diameter (mm)]. Furthermore,
the torque decrease factor of the steel wire is less than 7% in a
torsion-torque curve in a torsion-torque test wherein forward
twisting and then reverse twisting are applied. A preferred steel
cord has two steel wires bundled together substantially in parallel
and one steel wire is wound around this bundle. This steel cord is
made from steel wires having the diameter, tensile strength and
toughness characteristics set forth above, and also the ratio B/A
of the strength B of the twisted steel cord to the aggregate
strength A of the steel wires before they are twisted together into
the steel cord is 0.935 or over.
[0035] Therefore it is an object of this invention to provide an
apparatus and a process for producing high quality metallic mesh
from fine metallic threads that eliminates the difficulties in
leaching the continuous clad array of metallic fiber tow
encountered by the prior art.
[0036] Another object of this invention is to provide an apparatus
and a process for producing high quality metallic mesh from
metallic fiber tow wherein a clad array of metallic fiber tow is
formed into a mesh and subsequently is leached to remove the
cladding to provide a metallic mesh.
[0037] Another object of this invention is to provide an apparatus
and a process for producing high quality metallic mesh from a clad
array of metallic fiber tow that inhibits the individual fibers of
the metallic mesh from being ensnared with adjacent individual
metallic fibers of the metallic mesh.
[0038] Another object of this invention is to provide an apparatus
and a process for producing high quality metallic mesh from high
quality metallic tow with minimal broken fibers.
[0039] Another object of this invention is to provide an apparatus
and a process for producing high quality metallic mesh that is
capable of producing high quality metallic mesh in commercial
quantities at a reasonable manufacturing cost.
[0040] The foregoing has outlined some of the more pertinent
objects of the present invention. These objects should be construed
as being merely illustrative of some of the more prominent features
and applications of the invention. Many other beneficial results
can be obtained by applying the disclosed invention in a different
manner or modifying the invention with in the scope of the
invention. Accordingly other objects in a full understanding of the
invention may be had by referring to the summary of the invention
and the detailed description describing the preferred embodiment of
the invention.
SUMMARY OF THE INVENTION
[0041] A specific embodiment of the present invention is shown in
the attached drawings. For the purpose of summarizing the
invention, the invention relates to the process for making fine
metallic mesh, comprising the steps of cladding an array of
metallic wires with an array cladding material to provide an array
cladding. The array cladding is drawn for reducing the diameter
thereof and for reducing the corresponding diameters of each of the
metallic wires of the array within the array cladding for providing
a drawn array cladding of fine metallic fibers. The drawn array of
fine metallic fibers is formed into a metallic mesh thereby
creating a series of bends in the drawn array cladding for reducing
interaction between adjacent portions of the array cladding. The
array cladding material is removed for producing the metallic mesh
from the array of fine metallic fibers.
[0042] In a more specific example of the invention, the step of
cladding the array of metallic wires includes cladding a wire with
a wire cladding material to provide a wire cladding. An array of
the wire claddings is assembled and the assembled array of wire
claddings is clad with the array cladding material to provide an
array cladding. In one example of the invention, the step of
cladding the metallic wires includes electroplating a wire with a
wire cladding material to provide a wire cladding. The step of
drawing the array cladding may include a multiple drawing and
annealing process for producing a drawn array cladding of fine
metallic fibers.
[0043] In another more specific example of the invention, the step
of forming a series of bends in the drawn array cladding includes
forming a series of bends along the longitudinal length of the
drawn array cladding. The series of bends may be disposed in one
dimension or two dimensions perpendicular to a third dimension
extending along the longitudinal length of the drawn array
cladding.
[0044] Preferably, the series of bends in the array cladding
includes a continuous periodic series of curves in the array
cladding such as a continuous sinusoidal bend in the drawn array
cladding. The series of bends minimizes the direct contact between
adjacent portions of the drawn array cladding for minimizing
interaction between the array of fine metallic fibers after removal
of the array cladding material. Preferably, the array cladding
material is chemically removed for providing the metallic mesh
formed from an array of fine metallic fibers.
[0045] In another example of the invention, the invention is
incorporated into the process for making a fine metallic mesh from
a multiplicity of metallic threads wherein the metallic threads are
formed by drawing the array cladding for reducing the diameter
thereof and for reducing the corresponding diameters of each of the
metallic wires of the array within the array cladding for producing
a drawn array cladding of fine metallic fibers to function as a
thread for the fine metallic mesh. The threads of the drawn array
of fine metallic fibers are formed into a metallic mesh thereby
creating a series of bends in the drawn array cladding for reducing
interaction between adjacent portions of the array cladding. The
threads may be formed into a metallic mesh by weaving or braiding
the threads or any suitable textile process. The array cladding
material is removed for producing the metallic mesh from the array
of fine metallic fibers.
[0046] The foregoing has outlined rather broadly the more pertinent
and important features of the present invention in order that the
detailed description that follows may be better understood so that
the present contribution to the art can be more fully appreciated.
Additional features of the invention will be described hereinafter
which form the subject matter of the invention. It should be
appreciated by those skilled in the art that the conception and the
specific embodiments disclosed may be readily utilized as a basis
for modifying or designing other structures for carrying out the
same purposes of the present invention. It should also be realized
by those skilled in the art that such equivalent constructions do
not depart from the spirit and scope of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0047] For a fuller understanding of the nature and objects of the
invention, reference should be made to the following detailed
description taken in connection with the accompanying drawings in
which:
[0048] FIG. 1 is a block diagram illustrating a first process for
making a fine metallic mesh;
[0049] FIG. 2 is an isometric view of a metallic wire referred to
in FIG. 1;
[0050] FIG. 2A is an enlarged end view of FIG. 2;
[0051] FIG. 3 is an isometric view of the metallic wire of FIG. 1
after a wire cladding process;
[0052] FIG. 3A is an enlarged end view of FIG. 3;
[0053] FIG. 4 is an isometric view of an array of the wire
claddings of FIG. 3;
[0054] FIG. 4A is an end view of FIG. 4;
[0055] FIG. 5 is an isometric view of the array of the wire
claddings of FIG. 4 after a first array cladding process;
[0056] FIG. 5A is an end view of FIG. 5;
[0057] FIG. 6 is an isometric view similar to FIG. 5 illustrating
the array of the wire claddings of FIG. 4 after an alternate second
array cladding process;
[0058] FIG. 6A is an end view of FIG. 6;
[0059] FIG. 7 is an isometric view of the array cladding of FIG. 5
or FIG. 6 after a drawing process to provide a drawn array
cladding;
[0060] FIG. 7A is an enlarged end view of FIG. 7;
[0061] FIG. 8 is an isometric view of the drawn array cladding of
FIG. 7 after a weaving process;
[0062] FIG. 9 is an isometric view similar to FIG. 8 after removal
of an array cladding material and a wire cladding material
providing the fine metallic mesh formed from the fine metallic
fibers;
[0063] FIG. 10 is a block diagram illustrating a second process for
making a fine metallic mesh;
[0064] FIG. 11 is an isometric view of a metallic wire referred to
in FIG. 10;
[0065] FIG. 11A is an enlarged end view of FIG. 11;
[0066] FIG. 12 is an isometric view of the metallic wire of FIG. 11
after a wire cladding process;
[0067] FIG. 12A is an enlarged end view of FIG. 12;
[0068] FIG. 13 is an isometric view of the an array of the wire
claddings of FIG. 12;
[0069] FIG. 13A is an end view of FIG. 13;
[0070] FIG. 14 is an isometric view of the array of the wire
claddings of FIG. 13 after an array cladding process;
[0071] FIG. 14A is an end view of FIG. 14;
[0072] FIG. 15 is an isometric view of the array cladding of FIG.
14 after a drawing process;
[0073] FIG. 15A is an enlarged end view of FIG. 15;
[0074] FIG. 16 is an isometric view illustrating the partial
removal of the array cladding material of FIGS. 14 and 15;
[0075] FIG. 16A is an enlarged end view of FIG. 16;
[0076] FIG. 17 is an isometric view similar to FIG. 16 after the
total removal of the array cladding material leaving a remainer
comprising the wire clad material and the array of wires;
[0077] FIG. 17A is an enlarged end view of FIG. 17;
[0078] FIG. 18 is an isometric view of the remainder of FIG. 17
after a drawing process;
[0079] FIG. 18A is an enlarged end view of FIG. 18;
[0080] FIG. 19 is an isometric view of the drawn remainder of FIG.
18 after a braiding process;
[0081] FIG. 20 is an isometric view similar to FIG. 19 after
removal of the wire cladding material providing the fine metallic
mesh formed from the fine metallic fibers;
[0082] FIG. 21 is a block diagram illustrating a third process for
making a fine metallic mesh;
[0083] FIG. 22 is an isometric view of a metallic wire referred to
in FIG. 21;
[0084] FIG. 22A is an enlarged end view of FIG. 21;
[0085] FIG. 23 is an isometric view of the metallic wire of FIG. 22
after a wire cladding process;
[0086] FIG. 23A is an enlarged end view of FIG. 23;
[0087] FIG. 24 is an isometric view of the an array of the wire
claddings of FIG. 23;
[0088] FIG. 24A is an end view of FIG. 24;
[0089] FIG. 25 is an isometric view of the array of the wire
claddings of FIG. 24 after an array cladding process;
[0090] FIG. 25A is an end view of FIG. 25;
[0091] FIG. 26 is an isometric view of the array cladding of FIG.
25 after a drawing process;
[0092] FIG. 26A is an enlarged end view of FIG. 26;
[0093] FIG. 27 is a magnified view of a portion of FIG. 26A;
[0094] FIG. 28 is an isometric view of the drawn array cladding of
FIG. 27 after a process of braiding the drawn array cladding into a
specialized shape; and
[0095] FIG. 29 is an isometric view similar to FIG. 29 after
removal of the cladding material providing the fine metallic mesh
formed from the fine metallic fibers in a specialized shape.
[0096] Similar reference characters refer to similar parts
throughout the several Figures of the drawings.
DETAILED DISCUSSION
[0097] FIG. 1 is a block diagram illustrating a first process 10
for a making mesh 20 such as a fine metallic mesh 20. The process
10 of FIG. 1 comprises providing a metallic wire 30 selected of a
material suitable for making the fine metallic mesh 20.
[0098] FIGS. 2 and 2A are isometric and end views of the metallic
wire 30 referred to in FIG. 1. In this example, the metallic wire
30 is shown as a solid wire having an outer diameter 30D. The
metallic wire 30 may be an elemental wire such as nickel, an alloy
wire such as stainless steel or inconel, or a composite wire such
as copper and stainless steel. In this example, the metallic wire
30 is a stainless steel wire but it should be understood that
various types of materials may be used in the process 10 of the
present invention.
[0099] FIG. 1 illustrates the process step 11 of cladding the
metallic wire 30 with a wire cladding material 35 to provide a wire
cladding 40. The wire cladding material 35 may be applied to the
metallic wire 30 by a conventional cladding process or by an
electroplating process.
[0100] FIGS. 3 and 3A are isometric and end views of the wire
cladding 40 referred to in FIG. 1. The wire cladding material 35 is
applied to the outer diameter 30D of the metallic wire 30. The wire
cladding 40 defines an outer diameter 40D.
[0101] The process of applying the wire cladding material 35 to the
metallic wire 30 may be accomplished in various ways. Preferably,
the process of applying the wire cladding material 35 to the
metallic wire 30 is an electroplating process with the wire
cladding material 35 representing approximately ten percent (10%)
by weight of the combined weight of the metallic wire 30 and the
wire cladding material 35.
[0102] In this example, the wire cladding material 35 is a copper
material but it should be understood that various types of cladding
materials 35 may be used in the process 10.
[0103] Another preferred process of applying the wire cladding
material 35 to the metallic wire 30 is a conventional cladding
process. In a conventional cladding process, a strip of the wire
cladding material 35 is bent about the metallic wire 30 with the
opposed edges of the strip of the wire cladding material 35
abutting one another. The abutting edges of the strip of the wire
cladding 35 are welded to one another. For example, the wire
cladding material 35 may be carbon steel.
[0104] In another example of the invention, the metallic wire 30 is
encased within a preformed tube of the wire cladding material 35 to
form the wire cladding 40 having a diameter 40D. The metallic wire
30 is inserted within the preformed tube of the wire cladding 35 to
form the wire cladding 40.
[0105] FIG. 1 illustrates the process step 12 of assembling an
array 50 of a plurality of the wire claddings 40. The array 50 of
wire claddings 40 is assembled in a manner suitable for forming an
array cladding 60. Preferably, 150 to 3000 of the wire claddings 40
are assembled into the array 50.
[0106] FIGS. 4 and 4A are isometric and end views of the assembly
50 of a plurality of the wire claddings 40 after the assembly
process 12 of FIG. 1. Preferably, the array 50 of the wire
claddings 40 is arranged in a substantially parallel configuration
to form the array 50 of the wire claddings 40. In this example, the
array 50 of wire claddings 40 is assembled to have a substantially
circular cross-section.
[0107] FIG. 1 illustrates the process step 13 of cladding the array
50 of the wire claddings 40 to form an array cladding 60. The array
50 of the wire claddings 40 is encased within an array cladding
material 65 to form the array cladding 60 having a diameter 60D.
The array cladding material 65 may be made of various metallic
materials.
[0108] FIGS. 5 and 5A are isometric and end views illustrating a
first process of cladding the array 50 of the plurality of the wire
claddings 40 within the array cladding material 65A to provide the
array cladding 60. In this first process of cladding the array 50,
the array cladding material 65A is a preformed tube with the array
50 of the wire claddings 40 being inserted within the array
cladding material 65A.
[0109] FIGS. 6 and 6A are isometric and end views illustrating a
second alternative process of cladding the array 50 of the
plurality of the wire claddings 40 within the array cladding
material 65B to provide the array cladding 60. In this second
alternative process of cladding the array 50, a strip of the array
cladding material 65B is bent about the array 50 of the wire
claddings 40 with opposed edges of the strip of the array cladding
material 65B abutting one another. The abutting opposed edges of
the strip of the array cladding material 65B are welded to one
another. In this example, the array cladding material 65B is made
from a material different from the wire cladding material 35.
[0110] FIG. 1 illustrates the process step 14 of drawing the array
cladding 60. The process step 14 of drawing the array cladding 60
may include multiple drawings and annealing processes for
transforming each of the metallic wires 30 within the array
cladding material 65 into a fine metallic fiber 70. Furthermore,
the process step 14 of drawing the array cladding 60 transforms the
array cladding 60 into a clad metallic thread 75.
[0111] FIGS. 7 and 7A are isometric and end views of the clad
metallic thread 75 after the drawing process 14 of FIG. 1. The
process step 14 reduces an outer diameter 60D of the array cladding
60 and provides the clad metallic thread 75 having a outer diameter
75D. Furthermore, the process step 14 reduces the corresponding
outer diameter 40D of each of the plurality the wire claddings 40
and the corresponding outer diameter 30D of each of the metallic
wires 30 to provide the fine metallic fibers 70. The clad metallic
thread 75 is used for forming the fine metallic mesh 20.
[0112] FIG. 1 illustrates the process step 15 of forming the clad
metallic mesh 80 from a multiplicity of clad metallic threads 75.
The clad metallic threads 75 may be formed into the clad metallic
mesh 80 using any suitable textile process such as weaving,
braiding, darning and the like.
[0113] FIG. 8 is an isometric view of the clad metallic threads 75
formed into the clad metallic mesh 80. In this example, the
multiplicity of clad metallic threads 75 are formed into the clad
metallic mesh 80 by a weaving process having a multiplicity of
warps 81 and a multiplicity of weaves 82. The weaving process
creates a series of bends 84 extending along the longitudinal
length of each of the multiplicity of warps 81. Similarly, the
weaving process creates a series of bends 86 extending along the
longitudinal length of each of the multiplicity of weaves 82.
[0114] The multiplicity of weaves 82 are interleaved with the
multiplicity of warps 81 to create spaces 91 between each of the
adjacent warps 81. Similarly, the multiplicity of warps 81 are
interleaved between the multiplicity of weaves 82 to create spaces
92 between each of the adjacent weaves 82. The spaces 91 reduce
interaction between adjacent warps 81 whereas the spaces 92 reduce
interaction between adjacent weaves 82. The reduced interaction
between adjacent warps 81 and between adjacent weaves 82 is a
result of the minimized amount of parallel contact between adjacent
warps 81 and between adjacent weaves 82.
[0115] Each of the multiplicity of warps 81 makes perpendicular
contacts 94 with the multiplicity of the weaves 82. Similarly, each
of the multiplicity of weaves 82 makes perpendicular contacts 95
with the multiplicity of the warps 81. The perpendicular contacts
94 and 95 reduce interaction between the warps 81 and the weaves
82. The reduced interaction between warps 81 and the weaves 82 is a
result of the minimized amount of parallel contact between warps 81
and weaves 82.
[0116] FIG. 1 illustrates the process step 16 of removing the array
cladding material 65. The process step 16 of removing the array
cladding material 65 leaves an array of the fine metallic fibers 70
with each of the fine metallic fibers 70 being clad with the wire
cladding material 35.
[0117] The array cladding material 65 may be removed in a number of
ways including the removal by a chemical or electrochemical removal
process. In one example, the clad metallic mesh 80 is immersed into
a container for treatment by the chemical or electrochemical
removal process. After the removal of the array cladding material
65, the wire cladding material 35 remains about each of the fine
metallic fibers 70.
[0118] FIG. 1 illustrates the process step 17 of removing the wire
cladding material 35 remaining about each of the fine metallic
fibers 70. The wire cladding material 35 may be removed in a number
of ways including the removal by a chemical or electrochemical
removal process. In one example, the clad metallic mesh 80 is
immersed into a container for treatment by the chemical or
electrochemical removal process.
[0119] In an alternative to the present invention, the process step
17 of removing the wire cladding material 35 may be performed
serially or concurrently with the process step 16 of removing the
array cladding material 65. In this example, the array cladding
material 65 and the wire cladding material 35 are immersed into a
container for treatment by the chemical or electrochemical removal
process. The chemical or electrochemical removal process may first
remove the array cladding material 65 and secondly remove the wire
cladding material 35. In the alternative the chemical or
electrochemical removal process may remove simultaneously the array
cladding material 65 and the wire cladding material 35.
[0120] FIG. 9 is an isometric view of the fine metallic mesh 20
after the removal of the wire cladding material 35 to form the fine
metallic mesh 20. The fine metallic mesh 20 is formed by the
multiplicity of warps 81 and the interleaved multiplicity of the
weaves 82. Each of the multiplicity of warps 81 and weaves 82 is
formed from an array of fine metallic fibers 70.
[0121] During the process steps 14-16, the wire cladding material
35 compressed the array 50 of fine metallic fibers 70 into a
compacted array 50. After the removal of the wire cladding material
35, each of the fine metallic fibers 70 separates from adjacent
fine metallic fibers 70 thereby expanding to reduce the spaces 91
and 92 between the multiplicity of warps 81 and the multiplicity of
the weaves 82 to provide a more uniform fine metallic mesh 20.
Furthermore, the separation of the fine metallic fibers 70 provides
a tighter weave for the fine metallic mesh 20.
[0122] FIG. 10 is a block diagram illustrating a second process 110
for a making a fine metallic mesh 120. The process 110 of FIG. 10
comprises providing a metallic wire 130 selected of a material
suitable for making the fine metallic mesh 120.
[0123] FIGS. 11 and 11A are isometric and end views of the metallic
wire 130 referred to in FIG. 10. In this example, the metallic wire
130 is shown as a solid wire having an outer diameter 130D.
[0124] FIG. 10 illustrates the process step 111 of cladding the
metallic wire 130 with a wire cladding material 135 to provide a
wire cladding 140. The wire cladding material 135 may be applied to
the metallic wire 130 by a conventional cladding process or by an
electroplating process. In this example, the wire cladding material
135 comprises a coating material 135 applied by an electroplating
process.
[0125] FIGS. 12 and 12A are isometric and end views of the wire
cladding 140 referred to in
[0126] FIG. 10. The wire coating material 135 is applied to the
outer diameter 130D of the metallic wire 130. The wire cladding 140
defines an outer diameter 140D. In this example, the wire coating
material 135 is a copper material applied by an electroplating
process.
[0127] FIG. 10 illustrates the process step 112 of assembling an
array 150 of a plurality of the wire claddings 140. Preferably, 150
to 3000 of the wire claddings 140 are assembled into the array
150.
[0128] FIGS. 13 and 13A are isometric and end views of the array
150 of a plurality of the wire claddings 140 after the assembly
process 112 of FIG. 10. Preferably, the array 150 of the wire
claddings 140 is arranged in a substantially parallel configuration
to form the array 150 of the wire claddings 140.
[0129] FIG. 10 illustrates the process step 113 of cladding the
array 150 of the wire claddings 140 to form an array cladding 160.
The array 150 of the wire claddings 140 is encased within an array
cladding material 165 to form the array cladding 160 having a
diameter 160D.
[0130] FIGS. 14 and 14A are isometric and end views illustrating
the process of cladding the array 150 of the plurality of the wire
claddings 140 within the array cladding material 165 to provide the
array cladding 160. The process of cladding the array 150 may be
the process shown in FIG. 5 or the process shown in FIG. 6.
[0131] FIG. 10 illustrates the process step 114 of drawing the
array cladding 160. The process step 114 of drawing the array
cladding 160 may include multiple drawings and annealing
processes.
[0132] The process step 114 of drawing the array cladding 160
provides three effects. Firstly, the process step 114 reduces an
outer diameter 160D of the array cladding 160. Secondly, the
process step 114 reduces the corresponding outer diameter 140D of
each of the plurality of wire claddings 140 and the corresponding
outer diameter 130D of the metallic wires 130. Thirdly, the process
step 114 causes the coating materials 135 on each of metallic wires
130 to diffusion weld with the coating materials 135 on adjacent
metallic wires 130.
[0133] FIG. 15 is an isometric view of the array cladding 160 of
FIG. 14 after the drawing process. FIG. 15A is an enlarged end view
of FIG. 15. The drawing of the array cladding 160 causes the
coating material 135 on each of the plurality of metallic wires 130
to diffusion weld with the coating materials 135 on adjacent
plurality of metallic wires 130 to form a unitary material 166.
After the diffusion welding of the coating material 135, the
coating materials 135 are formed into the substantially unitary
material 166 extending throughout the interior of the array
cladding 160. The plurality of metallic wires 130 are contained
within the unitary material 166 extending throughout the interior
of the array cladding 160. Preferably, the coating material 135 is
a copper material and is diffusion welded within the array cladding
160 to form the substantially unitary copper material 166 with the
plurality of metallic wires 130 contained therein.
[0134] FIG. 10 illustrates the process step 115 of removing the
array cladding material 165. In the preferred form of the process,
the step 115 of removing the array cladding material 165 comprises
mechanically removing the array cladding material 165.
[0135] FIG. 16 is an isometric view illustrating the mechanical
removal of the array cladding material 165 with FIG. 16A being an
enlarged end view of FIG. 16. In one example of this process step
115, the array cladding material 165 is scored or cut at 167 and
168 by mechanical scorers or cutters (not shown). The scores or
cuts at 167 and 168 form tube portions 161 and 162 that are
mechanically pulled apart to peel the array cladding material
165.
[0136] A release material (not shown) may be deposited on the
cladding material 165 in a quantity sufficient to inhibit the
chemical interaction or bonding between the cladding material 165
and the array 150 of the metallic wires 130 and the coating
materials 135.
[0137] FIG. 17 is an isometric view illustrating the complete
removal of the array cladding material 165 with FIG. 17A being an
enlarged end view of FIG. 17. The removal of the array cladding
material 165 leaves a remainder 169. The remainder 169 comprises
the substantially unitary coating material 166 with the plurality
of metallic wires 130 contained therein. The remainder 169 defines
an outer diameter 169D.
[0138] FIG. 10 illustrates the process step 116 of drawing the
remainder 169 for reducing the outer diameter 169D thereof and for
reducing the corresponding outer diameter 130D of the array 150 of
metallic wires 130 contained therein. The process step 116 of
drawing the remainder 169 for transforming the metallic wires 130
within the remainder 169 into fine metallic fibers 170 having a
diameter 170D. Furthermore, the process step 116 of drawing the
remainder 169 transforms the remainder 169 into a clad metallic
thread 175.
[0139] FIG. 18 is an isometric view of the array 150 of metallic
wires 130 of FIG. 17 reduced into an array of fine metallic fibers
170 by the process step 116 of drawing the remainder 169. The
remainder 169 has been transformed into a clad metallic thread 175
having an outer diameter 175D. The clad metallic thread 175 is used
for forming the fine metallic mesh 120.
[0140] FIG. 18A is an enlarged end view of FIG. 18. The
substantially unitary material 166 provides mechanical strength for
the array of metallic wires 130 contained therein for enabling the
remainder 169 to be drawn without the array cladding material 165.
The substantially unitary material 166 enables the remainder 169 to
be drawn for reducing the outer diameter 169D thereof and for
providing the array of fine metallic fibers 170.
[0141] FIG. 10 illustrates the process step 117 of forming the clad
metallic mesh 180 from a multiplicity of the clad metallic threads
175. The clad metallic threads 175 may be formed into the clad
metallic mesh 180 using any suitable textile process such as
weaving, braiding, darning and the like.
[0142] FIG. 19 is an isometric view of the clad metallic threads
175 formed into the clad metallic mesh 180. In this example, the
multiplicity of clad metallic threads 175 are formed into the clad
metallic mesh 180 by a braiding process having a multiplicity of
first braids 181 and a multiplicity of second braids 182. The
braiding process creates a series of bends 184 extending along the
longitudinal length of each of the multiplicity of first braids
181. Similarly, the braiding process creates a series of bends 186
extending along the longitudinal length of each of the multiplicity
of second braids 182.
[0143] The multiplicity of second braids 182 are interleaved with
the multiplicity of first braids 181 to create spaces 191 between
each of the adjacent first braids 181. Similarly, the multiplicity
of first braids 181 are interleaved between the multiplicity of
second braids 182 to create spaces 192 between each of the adjacent
second braids 182. The spaces 191 reduce interaction between
adjacent first braids 181 whereas the spaces 192 reduce interaction
between adjacent second braids 182. The reduced interaction between
adjacent first braids 181 and between adjacent second braids 182 is
a result of the minimized amount of parallel contact between
adjacent first braids 181 and between adjacent second braids
182.
[0144] Each of the multiplicity of first braids 181 makes angular
contacts 194 with the multiplicity of the second braids 182.
Similarly, each of the multiplicity of second braids 182 makes
angular contacts 195 with the multiplicity of the first braids 181.
The angular contacts 194 and 195 reduce interaction between the
first braids 181 and the second braids 182. The reduced interaction
between first braids 181 and the second braids 182 is a result of
the minimized amount of parallel contact between first braids 181
and second braids 182.
[0145] FIG. 10 illustrates the process step 118 of removing the
unitary coating material 166. The process step 118 of removing the
unitary coating material 166 leaves an array of the fine metallic
fibers 170. The unitary coating material 166 may be removed in a
number of ways including the removal by a chemical or
electrochemical removal process. In one example, the clad metallic
mesh 180 is immersed into a container for treatment by the chemical
or electrochemical removal process.
[0146] FIG. 20 is an isometric view of the fine metallic mesh 120
after the removal of the unitary coating material 166 to form the
fine metallic mesh 120. The fine metallic mesh 120 is fabricated by
the braiding process and formed from an array of fine metallic
fibers 170.
[0147] During the process steps 114-117, the unitary coating
material 166 compresses the fine metallic fibers 170 into a
compacted array 150. After the removal of the unitary coating
material 166, each of the fine metallic fibers 170 separates from
adjacent fine metallic fibers 170 thereby expanding to provide a
more uniform fine metallic mesh 170 and a tighter braiding for the
fine metallic mesh 120.
[0148] FIG. 21 is a block diagram illustrating a third process 210
for a making a fine metallic mesh 220. The process 210 of FIG. 21
comprises providing a metallic wire 230 selected of a material
suitable for making the fine metallic mesh 220.
[0149] FIGS. 22 and 22A are isometric and end views of the metallic
wire 230 referred to in FIG. 21. In this example, the metallic wire
230 is shown as a solid wire having an outer diameter 230D.
[0150] FIG. 21 illustrates the process step 211 of cladding the
metallic wire 230 with a wire cladding material 235 to provide a
wire cladding 240. In this example, the wire cladding material 235
is a coating material 235 applied by an electroplating process.
[0151] FIGS. 23 and 23A are isometric and end views of the wire
cladding 240 referred to in FIG. 21. The wire coating material 235
is applied to the outer diameter 230D of the metallic wire 230. The
wire cladding 240 defines an outer diameter 240D. In this example,
the wire coating material 235 is a copper material applied by an
electroplating process.
[0152] FIG. 21 illustrates the process step 212 of assembling an
array 250 of a plurality of the wire claddings 240. Preferably, 150
to 3000 of the wire claddings 240 are assembled into the array
250.
[0153] FIGS. 24 and 24A are isometric and end views of the array
250 of a plurality of the wire claddings 240 after the assembly
process 212 of FIG. 21. Preferably, the array 250 of the wire
claddings 240 is arranged in a substantially parallel configuration
to form the array 250 of the wire claddings 240.
[0154] FIG. 21 illustrates the process step 213 of cladding the
array 250 of the wire claddings 240 to form an array cladding 260.
The array 250 of the wire claddings 240 is encased within an array
cladding material 265 to form the array cladding 260 having a
diameter 260D. In this example, the array cladding material 265 is
formed from the same type material as the wire coating material
235.
[0155] FIGS. 25 and 25A are isometric and end views illustrating
the process of cladding the array 250 of the wire claddings 240
within the array cladding material 265 to provide the array
cladding 260. The process of cladding the array 250 may be the
process shown in FIG. 5 or the process shown in FIG. 6.
[0156] FIG. 21 illustrates the process step 214 of drawing the
array cladding 260. The process step 214 of drawing the array
cladding 260 may include multiple drawings and annealing processes.
The process step 214 of drawing the array cladding 260 provides
four effects. Firstly, the process step 214 reduces an outer
diameter 260D of the array cladding 260. Secondly, the process step
214 reduces the corresponding outer diameter 240D of each of the
array 250 of wire claddings 240 and the corresponding outer
diameter 230D of the metallic wires 230. Thirdly, the process step
214 causes the coating materials 235 on each of metallic wires 230
to diffusion weld with the coating materials 235 on adjacent
metallic wires 230. Fourthly, the process step 214 causes the array
cladding material 265 to diffusion weld with the coating materials
235 on the metallic wires 230.
[0157] FIG. 26 is an isometric view of the array cladding 260 of
FIG. 25 after the drawing process. FIG. 26A is an enlarged end view
of FIG. 26. The drawing of the array cladding 260 causes the
coating material 235 on each of the plurality of metallic wires 230
to diffusion weld with the coating materials 235 on adjacent
plurality of metallic wires 230 to form a unitary material 266. The
array cladding material 265 diffusion welds to the coating
materials 235 on the metallic wires 230.
[0158] FIG. 27 is a magnified view of a portion of FIG. 26A. After
the diffusion welding of the coating material 235 and the array
cladding material 265, the coating materials 235 and the array
cladding material 265 are formed into the substantially unitary
material 266 extending throughout the array cladding 260. The
plurality of metallic wires 230 are contained within the unitary
material 266 extending throughout the array cladding 260.
Preferably, the coating material 235 and the array cladding
material 265 is a copper material and is diffusion welded to form
the substantially unitary copper material 266 with the plurality of
metallic wires 230 contained therein.
[0159] The process step 214 of drawing the array cladding 260
reduces the outer diameter 260D thereof and reduces the
corresponding outer diameter 230D of the metallic wires 230
contained therein. The process step 214 of drawing the array
cladding 260 transforms the metallic wires 230 within the array
cladding 260 into fine metallic fibers 270 having a diameter 270D.
Furthermore, the process step 214 of drawing the array cladding 260
transforms the array cladding 260 into a clad metallic thread 275
having an outer diameter 275D. The clad metallic thread 275 is used
for forming the fine metallic mesh 220.
[0160] FIG. 21 illustrates the process step 215 of forming the clad
metallic mesh 280 from a multiplicity of the clad metallic threads
275. The clad metallic threads 275 may be formed into the clad
metallic mesh 280 any suitable textile process such as braiding,
darning and the like.
[0161] FIG. 28 is an isometric view of the clad metallic threads
275 formed into the clad metallic mesh 280. In this example, the
multiplicity of clad metallic threads 275 are formed into the clad
metallic mesh 280 by a braiding process having a multiplicity of
first braids 281 and a multiplicity of second braids 282. The
braiding process creates a series of bends 284 extending along the
longitudinal length of each of the multiplicity of first braids
281. Similarly, the braiding process creates a series of bends 286
extending along the longitudinal length of each of the multiplicity
of second braids 282.
[0162] The multiplicity of second braids 282 are interleaved with
the multiplicity of first braids 281 to create spaces 291 between
each of the adjacent first braids 281. Similarly, the multiplicity
of first braids 281 are interleaved between the multiplicity of
second braids 282 to create spaces 292 between each of the adjacent
second braids 282. The spaces 291 reduce interaction between
adjacent first braids 281 whereas the spaces 292 reduce interaction
between adjacent second braids 282. The reduced interaction between
adjacent first braids 281 and between adjacent second braids 282 is
a result of the minimized amount of parallel contact between
adjacent first braids 281 and between adjacent second braids
282.
[0163] Each of the multiplicity of first braids 281 makes angular
contacts 294 with the multiplicity of the second braids 282.
Similarly, each of the multiplicity of second braids 282 makes
angular contacts 295 with the multiplicity of the first braids 281.
The angular contacts 294 and 295 reduce interaction between the
first braids 281 and the second braids 282. The reduced interaction
between first braids 281 and the second braids 282 is a result of
the minimized amount of parallel contact between first braids 281
and second braids 282.
[0164] In this example, the braiding process forms the clad
metallic mesh 280 into a specialized shape. In this example, the
first braids 281 and second braids 282 of the multiplicity of clad
metallic threads 275 are formed into cylinder 296 with a closed
hemispherical end 298. The cylinder 296 with the closed
hemispherical end 298 may be used as a gas burner for heating gas
fired boilers, ovens and furnaces or the like.
[0165] The specialized shape has been shown in this example as a
cylinder 296 with the closed hemispherical end 298 but it shown be
understood that the multiplicity of clad metallic threads 275 may
be formed in a wide variety of shapes and sizes.
[0166] FIG. 21 illustrates the process step 216 of removing the
unitary coating material 266. The process step 216 of removing the
unitary coating material 266 leaves an array of the fine metallic
fibers 270. The unitary coating material 266 may be removed in a
number of ways including the removal by a chemical or
electrochemical removal process.
[0167] FIG. 29 is an isometric view of the fine metallic mesh 220
after the removal of the unitary coating material 266 to form the
fine metallic mesh 220. After the removal of the unitary coating
material 266, each of the fine metallic fibers 270 separates from
adjacent fine metallic fibers 270 thereby expanding to provide a
more uniform fine metallic mesh 270 and a tighter braid for the
fine metallic mesh 220.
[0168] The present invention provides a process for making fine
metallic mesh suitable fro use as a filter media, catalyst carrier,
or any other suitable to a used for such fine metallic mesh.
Although the aforementioned specification has been set forth with
reference to making the stainless steel fine metallic mesh, it
should be understood that the apparatus and process of the
invention is suitable for use with a wide variety of metals and
types of fibers. It should be understood that various other
materials may be used in the present process and that the number
and dimensions set forth herein are only by way of example and that
once skilled in the art may vary the disclosed process based on the
disclosure of the present invention.
[0169] The present disclosure includes that contained in the
appended claims as well as that of the foregoing description.
Although this invention has been described in its preferred form
with a certain degree of particularity, it is understood that the
present disclosure of the preferred form has been made only by way
of example and that numerous changes in the details of construction
and the combination and arrangement of parts may be resorted to
without departing from the spirit and scope of the invention.
* * * * *