U.S. patent application number 10/317246 was filed with the patent office on 2003-06-12 for rigidified mesh structure and process for obtaining same.
Invention is credited to Schlanger, Jordan.
Application Number | 20030106800 10/317246 |
Document ID | / |
Family ID | 26980854 |
Filed Date | 2003-06-12 |
United States Patent
Application |
20030106800 |
Kind Code |
A1 |
Schlanger, Jordan |
June 12, 2003 |
Rigidified mesh structure and process for obtaining same
Abstract
The rigidified mesh structure includes filaments of at least one
of metal and non-metal assembled in a mesh configuration, wherein
the filaments are configured in a rigid structure by plating with
metal. Desirably, the filaments include adjacent contact points
which are fused together by the plated metal.
Inventors: |
Schlanger, Jordan;
(Saugerties, NY) |
Correspondence
Address: |
BACHMAN & LAPOINTE, P.C.
900 CHAPEL STREET
SUITE 1201
NEW HAVEN
CT
06510
US
|
Family ID: |
26980854 |
Appl. No.: |
10/317246 |
Filed: |
December 10, 2002 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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60339193 |
Dec 11, 2001 |
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Current U.S.
Class: |
205/76 ;
205/114 |
Current CPC
Class: |
C25D 7/005 20130101 |
Class at
Publication: |
205/76 ;
205/114 |
International
Class: |
C25D 005/02 |
Claims
What is claimed:
1. A rigid mesh structure, which comprises: filaments of at least
one of metal and non-metal assembled in a mesh configuration;
wherein said filaments are configured in a rigid mesh structure by
plating with metal.
2. A rigid structure according to claim 1, wherein said filaments
in said mesh configuration include adjacent contact points which
are fused together by said plated metal.
3. A rigid structure according to claim 2, wherein said filaments
are plated by electrodeposition with metal.
4. A rigid structure according to claim 2, wherein said filaments
are plated by electroless metal deposition.
5. A rigid structure according to claim 2, wherein said rigid mesh
structure is one of an article of jewelry and an ornamental
product.
6. A rigid structure according to claim 3, wherein said plated
metal is in a work hardened state.
7. A rigid structure according to claim 2, wherein said filaments
are one of glass and plastic.
8. A rigid structure according to claim 2, wherein said filaments
are one of braided and knitted.
9. A rigid structure according to claim 2, wherein said filaments
are one of glass, plastic metal wire and metal filaments.
10. A rigid structure according to claim 9, wherein said filaments
have a gage of 0.003 to 0.01 inch, and said plating has a thickness
of 0.005 to 0.05 inch.
11. A method for forming a rigid mesh structure, which comprises:
assembling filaments of at least one of metal and non-metal in a
mesh configuration; and plating said filaments with metal to form a
rigid mesh structure.
12. A method according to claim 11, wherein said filaments are
assembled in a mesh configuration with adjacent contact points, and
including the step of fusing said adjacent contact points together
by said plated metal.
13. A method according to claim 12, including the step of plating
said filaments by electrodeposition with metal.
14. A method according to claim 12, including the step of plating
said filaments by electroless metal deposition.
15. A method according to claim 12, including the step of forming
one of a rigid mesh article of jewelry and a rigid mesh ornamental
product.
16. A method according to claim 12, including the step of
assembling filaments of one of glass, plastic, metal wire and metal
filaments.
17. A method according to claim 12, including the step of
assembling filaments in one of a braided and knitted
configuration.
18. A method according to claim 16, wherein said filaments have a
gage of 0.003 to 0.01 inch, and said plating has a thickness of
0.005 to 0.05 inch.
Description
CROSS REFERENCE TO RELATED APPLICATION
[0001] This application claims the benefit of U.S. Provisional
Application S No. 60/339,193, Filed Dec. 11, 2001.
[0002] The present invention relates to a rigidified mesh structure
and a method of obtaining same. The present invention utilizes
metallic and/or non-metallic fibers using electrodeposition or
electroforming in order to rigidify the structure and fuse adjacent
fibers into a porous matrix.
[0003] In accordance with the present invention, individual fibers
or filaments of metal, wire or other metallic fibers or filaments
or non-metallic fibers or filaments are woven or otherwise
assembled into a mesh configuration. The resultant mesh
configuration includes a plurality of such fibers or filaments that
are freely formed into an assembled structure which may have wide
ranging configurations. The resultant formed mesh is subsequently
fused into a rigid structure in accordance with the present
invention. The rigidification process is achieved through
electrodeposition or electroforming, whereby the assembled fiber or
filament structure is immersed in a plating solution as cathode and
the desired metal is electroformed or electrodeposited onto the
mesh structure in a desired thickness in order to coat the mesh
structure and fuse adjacent contact points where the mesh structure
fibers contact each other. This results in a rigidified structure
including the base wire, fibers or filaments and coated metal
thereon to provide a highly stable and readily obtained structure
having the desired configurations. The resulting rigidified
structures are extremely pleasing from an aesthetic point of view
and may be used for a variety of applications, especially jewelry
or ornamental products, but not limited to these products.
[0004] The product and process of the present invention offers
extensive advantages.
[0005] Thus, rigid, light-weight three dimensional, mesh-like or
porous materials can be readily and easily formed in a range of
configurations not readily obtained by conventional processing.
[0006] Fibers and wires or other filaments can be readily woven or
formed into an enormous range of patterns by procedures such as
braiding or knitting, which allows an unlimited range of movement,
expansion and contraction. Also, the density of the woven material
and the size of the pores can be varied and one has the ability to
conform the base material to curved and compound curved surfaces or
the like. The subsequent rigidification process allows this
flexible, malleable lattice to be readily transformed into a rigid
metal structure with any degree of density or perforation desired.
Since braids, knits and other woven and non-woven mesh
constructions are highly engineered, and since metal deposits in
microscopic increments, the process of the present invention offers
tremendous control over pore-size, shape, density and weight of the
finished rigidified, metal coated structure.
[0007] The nature of most electro-deposited metals is to be
deposited in a work-hardened state, with a certain amount of
control over degrees of strength, hardness, spring, etc. Therefore
the rigidified structures of the present invention are able to be
made in a very light-weight range, as well as virtually any desired
heavier range, which are difficult to achieve with other metal
fabrication or forming processes.
[0008] Since the rigidification process of the present invention is
a cold-forming process, a structured mesh can easily be formed
around heat-sensitive items such as glass or plastic, which are
intended to become an integral part of the rigidified structure.
The cold-forming aspect also may include removable mandrills under
the fiber mesh, such as wax, which can be melted out of the formed,
perforated structure after rigidification.
[0009] The present invention is particularly suitable for the
manufacture of jewelry and home accessories, since the process of
the present invention allows for delicately filigreed, lightweight
and strong structures that are not readily manufacturable by any
other means. In this application, various decorative braided or
knitted structures are chosen for their aesthetic and functional
properties, and are generally woven from very fine wires into flat
or tubular configurations which are stretched and easily
cold-formed into desired three- dimensional shapes, such as for
jewelry components. Meshes of such delicacy woven from such fine
wires would never withstand wear. However, in accordance with the
present invention, fusing and rigidifying the forms in accordance
with the present invention into rigid, lightweight structures
offers numerous significant advantages.
[0010] Traditionally, mesh jewelry generally has to be formed from
heavy gauge wire in order to have enough strength to be worn,
resulting in difficulties, such as a limited range of patterns and
forms available as well as high costs for pressing tools to make
the forms, and a heavier, less economical use of material. The
process of the present invention allows much finer gauge wires to
be used, allowing much more delicate and intricate patterns that
would otherwise be too delicate to withstand wear. For example,
although any base mesh gage can be used, one can readily use base
wire or mesh gage of 0.008 inch, and preferably one uses base wire
or mesh gages of from 0.003-0.01 inch. The process of the present
invention retains the desired original highly detailed perforated
pattern, but by rigidifying and fusing all of the crossing points
the pattern is transformed into an extremely lightweight, rigid
structure with hardness, strength, and aesthetic delicacy from an
unstable and fragile structure.
[0011] Other traditional processes for manufacturing woven patterns
or filigreed structures, such as casting, stamping soldering are
not as suitable and do not allow the significant advantages of the
electroformed rigidification process of the present invention.
[0012] Thus, for example, casting generally requires a certain
minimum thickness for the metal to flow through and fill without
chilling or creating gaps in the casting. Lost wax casting requires
the manufacture of waxes, usually in rubber molds. Wax requires an
even larger cavity in order to fill properly. Both wax and metal
would chill before filling cavities of the dimension that the
electroformed rigidification process of the present invention
allows. In addition, there is a tendency for wax and metal to flash
across parting lines in the molds and cracks in the investment.
Moreover, cast metals are generally dead-soft and the delicate
structures would collapse and have no spring or memory. Also, few
casting alloys allow tempering and the process of the present
invention allows the use of fine gold and fine silver, for example,
which are difficult to cast and which produce extremely soft
castings. The process of the present invention allows light weight,
filigreed structures to be formed in these materials at close to
their maximum hardness. The finishing process of raw castings is
extensive and generally requires the abrasive removal of metal from
the surface, eroding surface detail. In the electroformed
rigidification process of the present invention, a metallic layer
can be applied with a very bright, high quality surface which
requires minimum abrasive finishing, preserving a high level of
detail in the finished object. Although a wide variety of coating
or plating thicknesses can be used, one preferably coats in the
range of 0.005 to 0.05 inch. In accordance with the present
invention, metal fibers can be braided or knitted in a tubular
configuration which can be stretched or deformed with or without
removable internal mandrills, allowing volumetric, filigreed
structures which lost-wax casting does not easily allow as
two-piece clamshell assemblies would be required.
[0013] On the other hand, stampings require expensive stages of
tooling and die-work and would be unable to adapt to any variations
in manufactured items, such as encasing a hand-blown crystal object
in silver mesh. Stamped filigree of any strength would not allow
variations in the integral glass mandrill. On the other hand, woven
wire is infinitely adaptable. In addition, volumetric forms would
require clamshell assemblies. Any hard-soldering of clamshell
assemblies would require annealing during assembly with resultant
loss of strength, and hot assembly prohibits the use of any
integral heat-sensitive components, i.e., soldering stamped
components around a crystal bowl would shatter the bowl. The
process of the present invention would allow filigreed mesh to be
cold-formed closely to the contour of the surface of the crystal
bowl with no soldered assembly required. Still further,
perforations in stamped sheets or other solid forms result in large
amounts of scrap. On the other hand, the process of the present
invention builds the structure from the inside out, and therefore
scrap is virtually eliminated.
[0014] Referring to soldering, a soldering process by definition,
adds molten metal to the item which tends to flow via capillary
action into the crossing points and pores of the assembly,
obscuring the detail and open structure desired. The heat involved
in soldering or other types of fusing, welding or sintering,
disallows the use of heat-sensitive integral mandrills as well as
removable mandrills, such as wax. Hard-soldering, required for
precious metals, will result in an annealed structure and loss of
strength.
[0015] The present invention is also readily adaptable to numerous
potential applications. For example, the process of the present
invention may be used to form intricately linked, rigidified
structures, such as chains or milanese mesh. Alternatively, one can
selectively rigidify by means of a stop-off (non-conductive
plating-resist material) applied to selected areas, allowing these
areas to remain flexible while their adjoining zones are
rigidified. The process of the present invention may be used
wherein the flexible mesh is formed or stretched over a removable
mandrill. For example, molded wax or other soluble or removable
substrate which is then removed, allowing the finished or
rigidified structure to retain the shape of the mandrill's contour
or volumetric form. The process of the present invention may be
used wherein the mandrill becomes an integral part of the product.
For example, forming woven or braided mesh over or around a glass
or stone object and rigidifying, resulting in a filigreed metal
structure applied to the surface of the mandrill. The process of
the present invention may be used where the metallic deposit is
achieved by electrodeposition as well as the so-called electroless
deposition such as electroless nickel. The process of the present
invention may also be used with non-conductive filaments such as
nylon, which are woven into a structure and rendered conductive by
an electrolyzing process, and rigidified as aforesaid. The process
of the present invention may also be used wherein three-dimensional
objects are created with fibers, either by compression into a die
or other means, in which fibers fill the full volume of the form,
as with compressed mesh bushings and washers. Still further, the
process of the present invention may be used wherein the rigidified
structure is used in place of other perforated structures, such as
expanded sheet metal or perforated sheet metal. In addition, the
process of the present invention may be used wherein a conductive
strip or foil tape is used in place of metal fibers.
[0016] In addition to the foregoing, the present invention is
readily susceptible to numerous other applications, such as
industrial applications. For example, rigid, perforated filters,
strainers with any desired mesh size or density may be easily
conformed to any mandrill shape, i.e., a cone-shaped or contoured
filter. In addition, the present invention may be used with EMI or
RFI electrical shielding applications, especially when shielding
mesh requires greater durability and/or rigidity. In addition, the
present invention may also be used with forming of a mesh component
over a non-conductive substrate. In addition, the present invention
may also be used with armoring delicate or soft elements, such as
rubber tubing, while possibly stopping off sections to allow
flexibility. In addition, the present invention may also be used to
create a seamless cage around objects which are allowed to move
freely within that cage. This is achieved by molding a removable
substrate such as wax, around said objects, forming flexible mesh
around the wax form, rigidifying and melting out the wax.
[0017] In addition to the foregoing, the present invention may be
used to create mechanically linked assemblies. For example,
hour-glass shaped connecting units may be first fabricated by die
swaging, machining, or any means. Units may be inserted into a mold
which contains a final pattern or linked assembly without
separation between the linked elements. The pattern is configured
so that areas which are to be later separated are necked down to a
dimension smaller than the widest diameter of hour-glass-shaped
units. The hour-glass-shaped units are inserted at these neck-down
junctures in the mold, and the electroformed matrix is molded
around them. In addition, a shell of metal may be electroformed
over the entire object as a single unit. Alternatively, the shell
may be cut apart at the junctures without cutting through the
hourglass inserts, and the mandrill may be melted out through the
resultant openings.
[0018] Advantageously, the present invention allows one to obtain
connected components that swivel or rotate universally, or
connected elements can be of any complex, varied shape that
electroforming allows, unlike die-swage ball chain which must be
symmetrical. The present invention also allows pull or push springs
to be strung through hour-glass units, effecting contraction of
series after spreading apart and vice-versa.
[0019] In the preferred embodiment one employs a base mesh of
copper, brass, silver, gold, nickel or steel or mixtures thereof.
Plating or coating metals preferably employed are copper, silver,
gold, platinum, nickel and combinations thereof.
EXAMPLE
[0020] An original form of a cuff bracelet in accordance with the
present invention is created from a mesh braided from
double-stranded 0.008" fine silver wire. This form is immersed into
a stainless steel plating tank with the following chemical mixture
at 105-110 degrees temperature:
1 Silver Cyanide: 14-16 oz/gallon Potassium Cyanide: 12-18
oz/gallon Potassium Carbonate: 2 oz/gallon Potassium Hydroxide: 0-4
oz/gallon Commercial Brightener: 4-6 oz/gallon
[0021] The anodes were fine silver and the cathode was the mesh
bracelet. The current used was approximately 3 amps per sq. foot of
cathode. The bracelet was plated for 6 hours to a thickness of
0.007-0.008" thickness on all sides, which was enough to fuse all
of the wire crossings as well as to add enough strength to the
bracelet to withstand wear, but light enough to preserve the open
structure of the mesh.
[0022] It is to be understood that the invention is not limited to
the illustrations described and shown herein, which are deemed to
be merely illustrative of the best modes of carrying out the
invention, and which are susceptible of modification of form, size,
arrangement of parts and details of operation. The invention rather
is intended to encompass all such modifications which are within
its spirit and scope as defined by the claims.
* * * * *