U.S. patent application number 11/087529 was filed with the patent office on 2005-12-08 for wire mesh panel and method.
Invention is credited to McGrenera, Patrick, Tueshaus, Ruediger.
Application Number | 20050272329 11/087529 |
Document ID | / |
Family ID | 34062798 |
Filed Date | 2005-12-08 |
United States Patent
Application |
20050272329 |
Kind Code |
A1 |
Tueshaus, Ruediger ; et
al. |
December 8, 2005 |
Wire mesh panel and method
Abstract
An assembly and method is provided for a decorative panel which
may be utilized as a screen, wall, or other structural surface
comprises a wire mesh woven with flat, substantially flat, or
planar surfaced wires mounted within transparent or translucent
sheets of glass, polycarbonate, plastic, and/or other glass-like
material. The wires comprise twisted portions within the weave
thereof whereby the twisting flat, substantially flat or planar
surfaces thereby produce a visual effect. During construction of
the panel, one or more sheets of binding material are positioned
between the transparent or translucent sheet along with the mesh.
The assembly is heated and compressed to thereby form a panel with
all components bound together.
Inventors: |
Tueshaus, Ruediger;
(Dorsten, DE) ; McGrenera, Patrick; (The
Woodlands, TX) |
Correspondence
Address: |
KENNETH L. NASH
P.O. BOX 680106
HOUSTON
TX
77268-0106
US
|
Family ID: |
34062798 |
Appl. No.: |
11/087529 |
Filed: |
March 23, 2005 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
11087529 |
Mar 23, 2005 |
|
|
|
10620544 |
Jul 16, 2003 |
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Current U.S.
Class: |
442/18 |
Current CPC
Class: |
B32B 2451/00 20130101;
Y10T 428/22 20150115; D03D 15/593 20210101; Y10T 428/249953
20150401; D10B 2503/04 20130101; B32B 17/06 20130101; Y10T 442/145
20150401; B32B 17/10422 20130101; B32B 17/10761 20130101; D03D
15/44 20210101; B29C 70/688 20130101; D10B 2401/062 20130101; B44C
5/0415 20130101; B32B 17/10009 20130101; B32B 17/10376 20130101;
D03D 15/00 20130101; D10B 2101/20 20130101; Y10T 428/24273
20150115; B32B 17/10036 20130101; B44F 1/066 20130101; B32B 15/08
20130101; B32B 17/10247 20130101; D03D 15/46 20210101; Y10T 442/129
20150401; Y10T 442/109 20150401; B44C 5/0461 20130101; B32B
17/10788 20130101; B32B 2307/412 20130101; B32B 15/02 20130101;
D10B 2503/02 20130101; D03D 9/00 20130101; B32B 17/10366 20130101;
D03D 15/49 20210101; B44F 1/045 20130101 |
Class at
Publication: |
442/018 |
International
Class: |
D04B 001/00 |
Claims
It is claimed:
1. A decorative layered panel assembly, comprising: at least two
outer layers comprised of substantially transparent or translucent
material; a flat wire woven mesh positioned between said outer
layers, said flat wire woven mesh being woven with a plurality of
flat wires; and one or more inner layers of substantially
transparent or translucent binding material which secures said at
least two outer layers and said flat wire woven mesh together.
2. The decorative layered panel assembly of claim 1, wherein at
least a portion of said plurality of flat wires comprise one or
more twists at spaced intervals.
3. The decorative layered panel assembly of claim 1, wherein said
spaced intervals vary in length.
4. The decorative layered panel assembly of claim 2, wherein each
twist is formed by rotating a portion of one of said plurality of
flat wires with respect to another portion of said one of said
plurality of flat wires.
5. The decorative layered panel assembly of claim 3, wherein said
flat wire is rotated less than or equal to 360 degrees.
6. The decorative layered panel assembly of claim 5, wherein said
flat wire is rotated 180 degrees.
7. The decorative layered panel assembly of claim 2, wherein each
of said one or more twists is contained completely within an
individual one of said plurality of flat wires.
8. The decorative layered panel assembly of claim 1, wherein said
plurality of flat wires are comprised of metallic material.
9. The decorative layered panel assembly of claim 1, wherein said
at least two outer layers and said flat wire woven mesh is secured
together with said binding material as a result of pressure applied
to said panel and heating to panel.
10. The decorative layered panel assembly of claim 1, wherein said
one or more inner layers are created from one or more sheets of
said binding material positioned between said at least two outer
layers.
11. A method for making a panel, said method comprising: providing
at least two sheets of translucent or transparent material;
providing a woven mesh comprised of a plurality of flat wires;
providing one or more sheets of binding material; inserting said
woven mesh and said one or more sheets of binding material between
said at least two sheets of translucent or transparent material to
form an assembly; and melting said one or more sheets of binding
material for adhering said at least two sheets of translucent or
transparent material and said woven mesh together with said binding
material.
12. The method of claim 11, further comprising heating said
assembly sufficiently to melt said one or more sheets of binding
material but not enough to melt said at least two sheets of
translucent or transparent material or said woven mesh.
13. The method of claim 12, further comprising heating said
assembly less than one thousand degrees Centigrade.
14. The method of claim 11, further comprising applying pressure to
said assembly during said step of heating.
15. The method of claim 11, further comprising forming one or more
twists within one or more individual ones of said plurality of flat
wires.
16. The method of claim 15, further comprising forming said one or
more twists while weaving said woven mesh.
17. The method of claim 15, wherein said one or more twists
comprise a plurality of twists, said method further comprising
positioning said plurality of twists in said woven mesh at
repeatable spacings with respect to each other.
18. The method of claim 15, wherein said one or more twists
comprise a plurality of twists, said method further comprising
positioning said plurality of twists in said woven mesh at
non-repeated spacings with respect to each other.
19. The method of 11, further comprising providing that said
plurality of flat wires are comprised of metallic material.
20. The method of claim 19, further comprising providing that said
plurality of flat wires comprise a diameter of 0.5 millimeters or
less.
21. A layered panel, comprising: one or more layers of glass-like
material; and a wire mesh mounted within said one or more layers of
glass-like material, said wire mesh comprising a first plurality of
wires and a second plurality of wires, said first plurality of
wires being interwoven or knitted with said second plurality of
wires, said first plurality of wires comprising a non-circular
cross-section.
22. The layered panel of claim 21, said first plurality of wires
further comprising a plurality of twisted portions wherein said
non-circular cross-section is rotated.
23. The decorative panel of claim 21, wherein said twisted portions
are spaced apart with respect to each other.
24. The decorative panel of claim 22, wherein said twisted portions
are spaced apart with respect to each other at varying distances
with respect to each other.
25. The decorative panel of claim 21, further comprising binding
material to bind said one or more layers of glass-like material
with said wire mesh.
Description
[0001] This application is a continuation-in-part of U.S. patent
application Ser. No. 10/620,544 filed Jul. 16, 2003.
TECHNICAL FIELD
[0002] The present invention relates generally to a wire mesh panel
and, in one possible embodiment, to a wire mesh panel comprised of
generally planar wires which may also comprise flat wires with
twists therein.
BACKGROUND
[0003] Safety glass, also known as wired glass, is well known in
the prior art. Safety glass may utilize a wire mesh support as
discussed in more detail in the cited patents listed hereinafter.
Safety glass is utilized to provide protective windows that permit
visual perception therethrough. Accordingly, the wire mesh utilized
in prior art safety glass is typically of very small diameter wire
with wide openings in the mesh so as to avoid obstructing vision
through the glass. Due to the small diameter wire mesh with large
openings therein that permit maximum vision therethrough, there is
effectively very little inherent strength in this wire mesh. To
increase the strength of the wire mesh utilized in safety glass,
the wire mesh is formed by twisting the wires together at each
connection and/or welding the mesh.
[0004] The prior art safety glass focuses on minimizing the
appearance of the wire inside the glass. The result of using
relatively few strands of minimized diameter wire in the support
mesh significantly improves the ability to look through the glass
by blocking only a very small percent or a fraction of a percent of
the light through the safety glass, but also provides a relatively
low strength glass support structure as compared to many other
reinforcing materials.
[0005] The following patents show prior art related to the
above:
[0006] U.S. Pat. No. 2,511,168, issued Jun. 13, 1950, to J. S.
Martin et al., discloses the construction and mounting of units of
transparent synthetic resins, such as sheets, panels and structural
components, and proposes a mounting extension or member secured to
and projecting from the unit in such a manner that for all
practical purposes it becomes an integral part thereof and embodies
all the favorable characteristics of the unit, at the same time
avoiding and eliminating the disadvantages which have heretofore
characterized the mounting of elements or units.
[0007] U.S. Pat. No. 3,953,630, issued Apr. 27, 1976, to Roberts et
al., discloses a laminated transparent assembly suitable for use as
a windscreen for a high speed vehicle, e.g., an aircraft or railway
locomotive, which comprises a load-bearing sheet of toughened glass
having a second sheet of glass laminated thereto by means of an
impact resistant interlayer of plastics material, e.g.,
polyvinylbutyral, and an insert of high tensile strength flexible
material which extends around the periphery of the interlayer and
which has an inner part embedded in the outer marginal portion of
the interlayer in a plane parallel to the surfaces of the
interlayer, and an outer part extending outwardly beyond the edges
of the interlayer to provide for attachment of the assembly to the
structure of the vehicle. The insert is preferably a sheet of
fabric material, e.g., a fabric woven from rubber-impregnated glass
fiber cords and nylon, with the glass fiber cords substantially
perpendicular to the adjacent edges of the assembly, embedded
between layers of soft polyvinylbutyral. The outer part of the
insert may have a flexible portion adjacent to the edges of the
interlayer and an outer marginal portion which is reinforced, e.g.,
with metal, to render it rigid to provide means for attachment of
the assembly to the vehicle structure.
[0008] U.S. Pat. No. 3,954,547, issued May 4, 1976, to Werner
Genthner, discloses the production of safety glass with a plastic
sheet as an intermediate layer, using wires such as electrical
heating wires, which are fixed on the plastic sheet in their final
(for instance, undulating) shape in a stress free condition.
[0009] U.S. Pat. No. 4,020,217, issued Apr. 26, 1977, to Karasudani
et al., discloses a laminated safety glass structure which
comprises at least two glass sheets bonded to each other through an
interlayer of a plasticized polyvinyl acetyl resin treated with a
specific modified siloxane alone or together with a specific alkali
metal or alkaline earth metal salt of an organic mono- or
di-carboxylic acid. This structure has a highly improved
penetration resistance along with superior transparency, aging
resistance and weatherability, and is suitable for use as
windowpanes in transportation facilities and buildings.
[0010] U.S. Pat. No. 4,173,668, issued Nov. 6, 1979, to Hentzelt et
al., discloses a fire-screening panel that maintains its
effectiveness in preventing fire propagation even after aging of
the panel. The panel comprises a first structural ply formed from a
vitreous sheet, and a second structural ply, with a layer of
intumescent material disposed therebetween. Other plies may also be
provided, and the plies are clamped together in face-to-face
relationship, and/or bonded together. At least one ply of the panel
has an infra-red reflecting coating disposed thereon, remote from
the intumescent material, which coating provides for the retained
effectiveness of the fire-propagating properties of the panel
despite aging thereof.
[0011] U.S. Pat. No. 4,173,672, issued Nov. 6, 1979, to Jose R.
Mannheim, discloses a method to decorated laminate glass comprised
of two glass sheets joined by a decorated film of a thermoplastic
polymer. A sheet of glass, the film and a lamina of cellulosic
material, decorated on the surface that contacts the film, are
subjected to pressure and heat so as to transfer, by sublimation,
the decoration to the film at the moment that it adheres itself to
the surface of the glass. A second sheet of glass is over-placed on
the decorated film and pressed to it, with heat, so as to form a
safety glass decorated and/or colored in the interior.
[0012] U.S. Pat. No. 4,642,255, issued Feb. 10, 1987, to Frank C.
Dlubak, discloses a laminated article comprising two outer glass
layers, a polyvinyl acetyl layer disposed therebetween and a
fibrous layer encapsulated in the polyvinyl acetyl layer; and a
process for producing the laminated article comprising (1)
maintaining a substantially constant vacuum in a flexible container
containing an assembly comprising (a) a first glass layer, (b) a
first polyvinyl acetyl layer in contact with the first glass layer,
(c) a fibrous layer in contact with the first polyvinyl acetyl
layer, (d) a second polyvinyl acetyl layer in contact with the
fibrous layer and (e) a second glass layer in contact with the
second polyvinyl acetyl layer; (2) applying pressure on the
container while increasing the same from about ambient pressure to
an elevated pressure level and simultaneously increasing the
temperature on the contents of the container from about ambient
temperature to an elevated temperature level; (3) reducing the
temperature on the contents of the container from the elevated
temperature level to about ambient temperature; and then (4)
reducing the pressure on the container from the elevated pressure
level to about ambient pressure.
[0013] U.S. Pat. No. 4,824,722, issued Apr. 25, 1989, to Kenneth B.
Jarrett, discloses a safety glass laminate comprising a first sheet
of organic or inorganic glass and a second rigid sheet, which may
also be of organic or inorganic glass, with a flexible plastics
interlayer therebetween bonded to each of the sheets by adhesive
which has been cured by irradiation, the interlayer comprising two
outer layers of plastics film and an inner layer of fabric,
preferably woven polyester, interposed therebetween. The laminate
may, for example, be employed as decorative cladding or as a panel
for a glass door. A security window may be provided in the
laminate.
[0014] U.S. Pat. No. 5,219,630, issued Jun. 15, 1993, to James A.
Hickman, discloses a fire-resistant safety glazing product which
comprises at least two sheets of glazing material, e.g. glass,
bonded together with an interlayer of adhesive binder material and
metallic wire mesh of the type used in "wired glass" embedded in
the interlayer. Methods of manufacturing fire-resistant safety
glazing products are disclosed.
[0015] U.S. Pat. No. 5,230,954, issued Jul. 27, 1993, to Sakamoto
et al., discloses a fire protective glass panel for use in a fire
protective window, door, and partition wall, which comprises at
least one sheet of fireproof glass plate and a fluorocarbon resin
film of a chain molecular structure type bonded to a side surface
of the glass plate and which has non-shattering property as well as
fire protection property wherein the fireproof glass plate is a
heat-resistant and light transparent crystallized glass plate or,
alternatively, the fireproof glass plate is a wire glass plate and
the fluorocarbon resin film has a thickness of 0.02-1 mm and is
made of one of FEP, PFA, PCTFE, ETFE, and PVDF.
[0016] U.S. Pat. No. 5,462,805, issued Oct. 31, 1995, to Sakamoto
et al., discloses a fire-protection and safety glass panel having a
transparent appearance and dual functions as a fire protection
glass for shutting out flame and smoke for a long period of time
upon occurrence of fire and as a safety glass which is neither
shattered into pieces nor forms any through hole if it is broken in
an ordinary life. A PET (polyethylene terephthalate) film is
arranged between a first glass plate and a second glass plate. The
first and the second glass plates and the PET film are adhered
through transparent acrylic adhesive agent layers, respectively. An
intermediate resin layer comprises the PET film and the adhesive
agent layers and has a thickness between 75 and 200
micrometers.
[0017] U.S. Pat. No. 5,506,051, issued Apr. 9, 1996, to
Levy-Borochov et al., discloses an improved transparent
bullet-proof laminate which is formed with an energy absorbing
transition layer located between preformed laminae of glass and/or
plastic, such as polycarbonate, the transition layer constituting a
cured aliphatic urethane acrylate with optionally up to 70% of a
monofunctional monomeric acrylate, the transition layer in liquid
form having a viscosity preferably no greater than 1000 cps and in
cured state having a toughness of at least 0.1 MPa, and elastic
modulus no greater than 25 MPa and an elongation of at least
20%.
[0018] U.S. Pat. No. 5,908,704, issued Jun. 1, 1999, to Friedman et
al., discloses optical and fire screening protective glazing
laminates comprising fluoropolymer interlayer films. The films and
their laminates comprise THV and blends of THV with FEP, ECTFE or
ECCTFE, and modified with additives, such as coupling agents,
pigment or color concentrates, and IR- or UV-light blockers, and
may be subjected to a surface corona treatment. The films also may
incorporate a fiber mesh for additional reinforcement.
[0019] U.S. Pat. No. 5,944,862, issued Aug. 31, 1999, to Stephen
Edwin Howes, discloses a decorative window which consists of thick
transparent plastic resin layer laminated to a sheet of glass. The
outer surface of resin layer includes decorative features, such as
deeply contoured pictographic images and finely detailed textured
surfaces. The decorative window is produced as replica of a glass
master originally made using conventional grinding and surfaces
finishing techniques. The master is then covered with a mixture of
silicone, catalysts for curing the silicone, and a light oil to
form a mold. After curing, the mold is removed from the glass
master, inverted and a glass sheet, which has been prepared for the
process by being coated with organosilane ester, is clamped
thereto. The mold cavity is then filled with a mixture of a clear
plastic resin, catalysts for curing the resin, and organosilane
ester. After curing, the replicated decorative window is removed
from the mold.
[0020] U.K. Patent Application GB 2,078,166A, published Jan. 6,
1982, to Ugo Pacella, discloses composite sheet material that is
built-up of a plurality of single plates joined together by means
of one or more interposed biadhesive tapes. The composite sheet may
be provided with a colored or reflecting film and may comprise in
addition inserts formed of films or wires provided for increasing
the strength of the sheet or for serving as parts of electric
heating or alarm circuits. The process for making the sheets
provides for the application of the biadhesive tapes without the
forming of air pockets and for a compression effect acting over the
whole surface of the composite sheet within an autoclave. The
single plates forming the sheet may be of glass, polycarbonate, or
other synthetic material. The biadhesive tape is preferably
provided on both sides with a protective film, to be removed before
the application of the tape and the adhesive securement together of
the single plates.
[0021] U.K. Patent Application GB 2,125,732A, published Mar. 14,
1984, to Carl-Zeiss-Stiftung, discloses a composite glass and/or
vitreous ceramic-bonded system for application as shielding against
microwave radiation which comprises between at least one supporting
plate and at least one cover plate made of glass and/or vitreous
ceramic material, a metallic microwave-impermeable shield which is
non-detachably adhesively bonded to the plates by means of a
viscously elastic and/or permanently elastic cement, the metallic
shield being conducted in out of the bonded unit in such a manner
as to enable it being connected in microwave sealed fashion to an
adjoining frame and/or to mounting means. The composite system may
be used, for example, as a viewing or observation panel for
microwave-charged chambers.
[0022] U.K. Patent Application GB 2,155,856A, published Oct. 2,
1985, to James Arthur et al., discloses a method of producing a
laminate which comprises arranging a pair of sheets, e.g. of glass,
face-to-face and at an incline to the horizontal with a lower
portion of the periphery of the sheets sealed in a substantially
liquid tight manner by non-porous adhesive strip material
sandwiched between the sheets. Settable liquid resin material is
poured between the sheets through at least one filling opening
along an upper portion of the periphery of the sheets. When all the
resin material has been introduced, the upper portion of the sheet
periphery is sealed with the exception of air gaps, the sheets are
lowered to a horizontal position to enable air to be expelled
through the air gaps, and the liquid resin material is allowed to
set.
[0023] The above patents do not disclose solutions to the problems
discussed above. Consequently, there remains a need to provide an
improved glass or glass-like translucent or transparent material
with embedded decorative metal. Those of skill in the art will
appreciate the present invention which addresses the above and
other problems.
SUMMARY OF THE INVENTION
[0024] An objective of the present invention is to provide an
improved panel with a decorative metallic reinforcement.
[0025] Another objective the present invention is to provide a
means for selectively controlling light reflected by, passing
through, or diffused by a decorative wire mesh panel embedded in
translucent or transparent material.
[0026] These and other objectives, features, and advantages of the
present invention will become apparent from the drawings, the
descriptions given herein, and the appended claims. However, it
will be understood that above or below-listed and other stated
objectives and/or advantages of the invention are intended only as
an aid in quickly understanding aspects of the invention, are not
intended to limit the invention in any way, and therefore do not
form a comprehensive or restrictive list of objectives, and/or
features, and/or advantages.
[0027] In one preferred embodiment, the present invention provides
for a decorative layered panel assembly which may comprise one or
more elements such as, for instance, at least two outer layers
comprised of substantially transparent or translucent material
and/or a woven wire mesh positioned between the outer layers
wherein the woven mesh may preferably be woven with a plurality of
flat wires and/or one or more inner layers of substantially
transparent or translucent binding material which secures the at
least two outer layers and the woven wire mesh together. In one
possible preferred embodiment, at least a portion of the plurality
of flat wires comprise one or more twists at spaced intervals. The
spaced intervals the twists may or may not vary in length. Each
twist may be formed by rotating a portion of one of the plurality
of flat wires with respect to another portion of the one of the
plurality of flat wires. In one embodiment, flat wire is rotated
less than or equal to 360 degrees. In another embodiment, the flat
wire is rotated 180 degrees. In a preferred embodiment, each twist
is contained completely within an individual one of the plurality
of flat wires.
[0028] The binding material may preferably but not necessarily
comprise a material which melts at less than one degrees
Centigrade. In one embodiment, the two outer layers and the woven
wire mesh may then be secured together with the binding material as
a result of pressure applied to the panel and heating to panel. The
inner layers may be created from one or more sheets of the binding
material positioned between the at least two outer layers.
[0029] In one embodiment of the invention, a method for making a
panel is disclosed wherein the method may comprise one or more
steps such as, for example, providing at least two sheets of
translucent or transparent material, providing a woven mesh
comprised of a plurality of flat wires, providing one or more
sheets of binding material, inserting the woven mesh and the one or
more sheets of binding material between the at least two sheets of
translucent or transparent material to form an assembly and/or
heating the assembly to melt the one or more sheets of binding
material for adhering the at least two sheets of translucent or
transparent material and the woven mesh together with the binding
material.
[0030] The method may further comprise heating the assembly to melt
the one or more sheets of binding material but not enough to melt
the at least two sheets of translucent or transparent material or
the woven mesh. In one embodiment, the method may further comprise
heating the assembly less than one thousand degrees Centigrade
and/or may further comprise applying pressure to the assembly
during the step of heating.
[0031] In one embodiment, the method may comprise forming one or
more twists within one or more individual ones of the plurality of
flat wires and/or may comprise forming one or more twists while
weaving the woven mesh. The method may further comprise positioning
the plurality of twists in the woven mesh at repeatable spacings
with respect to each other. The method may further comprise
positioning the plurality of twists in the woven mesh at
non-repeated spacings with respect to each other.
[0032] In another embodiment, the present invention may comprise
one or more layers of glass-like material and a wire mesh mounted
within the one or more layers of glass-like material. The wire mesh
may comprise a first plurality of wires and a second plurality of
wires. The first plurality of wires may be interwoven or knitted
with the second plurality of wires. The first plurality of wires
may comprise a non-circular cross-section. The first plurality of
wires may further comprise a plurality of twisted portions wherein
the non-circular cross-section is rotated. The twisted portions
may, if desired, be spaced apart with respect to each other. As
well, the twisted portions may be spaced apart with respect to each
other at varying distances with respect to each other.
[0033] Accordingly, the present invention provides a method for
making construction material comprising a decorative panel
comprising one or more steps such as, for instance, determining a
desired amount of light to be passed by the flat panel ranging from
zero percent to eighty-five percent, and/or controlling
construction of a wire mesh comprising a first plurality of wires
and a second plurality of wires to provide the desired amount of
light to be passed by the flat panel, and/or mounting the wire mesh
to the one or more plates of substantially transparent
material.
[0034] The step of controlling may comprise controlling at least
two of a group consisting of selecting a wire mesh weave, selecting
twists in wires, selecting a percentage of open regions of the wire
mesh, selecting one or more cross-sectional shapes for the first
plurality of wires and the second plurality of wires, selecting a
diameter of the first plurality of wires and the second plurality
of wires.
[0035] In another embodiment, a method comprises one or more steps
such as determining a desired amount of light to be reflected by
the flat panel ranging from fifteen percent to one hundred percent,
and/or controlling construction of a wire mesh comprising a first
plurality of wires and a second plurality of wires to provide the
desired amount of light to be reflected by the flat panel, and/or
mounting the wire mesh to the one or more plates of substantially
transparent material.
[0036] The step of controlling may comprise controlling at least
two of a group consisting of selecting a wire mesh weave, selecting
twists in wires, selecting a percentage of open regions of the wire
mesh, selecting one or more cross-sectional shapes for the first
plurality of wires and the second plurality of wires, selecting a
diameter of the first plurality of wires and the second plurality
of wires, selecting a texture of the first plurality of wires,
selecting a type of metal or alloy, and the second plurality of
wires and selecting a reflectance of the first plurality of wires
and the second plurality of wires.
[0037] In another embodiment the invention comprises producing a
substantially flat and easily cleaneable smooth surface with an
internal decorative and textured wire screen.
[0038] The present invention comprises, in another embodiment
thereof, a decorative construction assembly. The invention may
comprise one or more elements such as, for instance, one or more
substantially transparent panels and/or a wire mesh mounted within
therein. The substantially flat panel may be rigid but could also
be substantially bendable. The wire mesh may comprise a first
plurality of wires and a second plurality of wires in at least one
weave pattern or knitted pattern. In one embodiment, the wire mesh
may act as a curtain in the glass whereby light passes but it is
difficult to see what is behind the panel, especially from a
distance. This embodiment may be of use for a dressing curtain or
shower enclosure. The first plurality of wires may be interwoven
with a second plurality of wires. The wire mesh may be woven with a
twilled weave or variation thereof and/or the wire mesh may be
woven in a Dutch weave or variation thereof and/or the wire mesh
may be woven in a heddle weave or variation thereof. A few examples
of other weaves include plain weave, twill weave, 5-heddle weave
and/or other woven variations. The first plurality of wires may
interconnect with the second plurality of wires at a plurality of
intersections. Each of the plurality of intersections may comprise
individual wires extending therefrom, whereby the individual wires
engage each other but are preferably not twisted around each other
so as to loop around each other. The second plurality of wires may
have a cross-section with at least one planar side. Either the
first plurality of wires or the second plurality of wires may have
a non-round cross-section.
[0039] The decorative construction assembly may further comprise a
transparent adhesive for securing the wire mesh within at least one
first layer of substantially transparent material and at least one
second layer of substantially transparent material. The wire mesh
may have a surface area and may define openings therein that permit
light through the wire mesh, whereby a percentage of the openings
with respect to a total surface area of the wire mesh is in a range
from zero to eighty-five percent. Alternative the range of open
area may be smaller such as between zero and twenty percent or
forty percent. The wire mesh may have a lustrous surface.
[0040] In another embodiment, the decorative construction material
may comprise one or more elements, such as, for instance, weaving
or knitting a first plurality of wires with a second plurality of
wires to form a wire mesh. Depending on the embodiment, the wires
may or may not be welded. In another embodiment, a metallic plate
or sheet may also be stamped and/or stamped to produce an opening
and which is then widened. The individual wires in the wire mesh
preferably intersect without looping completely around each other.
However, the mesh could be knitted by utilizing a plurality of
knitting needles. The wire mesh preferably has between zero and
eighty five percent open areas through the mesh. However, the wire
mesh openings could also be between zero and fifty, forty, thirty,
or twenty percent, depending on the decorative design. In one
embodiment, the wire mesh may be mounted between a plurality of
substantially transparent panels in laminar construction and may
preferably be affixed to the plurality of substantially transparent
panels. In another embodiment, the wire mesh may be integral or
melted into the transparent panels. The wire mesh may be affixed by
adhering the wire mesh to the plurality of substantially
transparent panels and/or by fastening the wire mesh to the
plurality of substantially transparent panels with a fastener.
[0041] The decorative construction material may be constructed into
an assembly that may be used to form a portion of a building wall,
and/or the decorative construction material may be constructed into
an assembly that may be used to form a portion of an article of
furniture. Many other construction uses are also possible, e.g.,
counter tops, glass curtains, shower enclosures, cubical walls, and
the like.
[0042] A wall portion may comprise a wire mesh embedded within a
plurality of translucent panels. The wire mesh may comprise woven
filaments in a selected weave pattern such that open area through
the wire mesh comprises less than eighty-five percent of an overall
area of the wire mesh. The wall portion is preferably mounted. In
one embodiment, the wall portion may be mounted in furniture. In
another embodiment, the wall portion may be mounted as a wall for a
building.
[0043] In one embodiment, the wire mesh may possibly be cut into a
desired pattern, such as, for example only, geometric patterns,
animal patterns, circles, automobiles, or any other types of
patterns. The wire mesh preferably contains a lustrous surface.
[0044] This summary is not intended to be a limitation with respect
to the features of the invention as claimed, and this and other
objects can be more readily observed and understood in the detailed
description of the preferred embodiment and in the claims.
BRIEF DESCRIPTION OF DRAWINGS
[0045] For a further understanding of the nature and objects of the
present invention, reference should be had to the following
detailed description, taken in conjunction with the accompanying
drawings, in which like elements are given the same or analogous
reference numbers and wherein:
[0046] FIG. 1 is a perspective view showing one embodiment of a
decorative wire mesh embedded in glass, plastic, or other
preferably relatively clear materials, in accord with the present
invention;
[0047] FIG. 2 is a perspective view showing another embodiment of a
decorative wire mesh embedded in glass, plastic, or other
preferably relatively clear materials, in accord with the present
invention;
[0048] FIG. 3 is an elevational view, in cross-section, of yet
another embodiment of a decorative wire mesh in glass, plastic, or
other preferably relatively clear materials, in accord with the
present invention;
[0049] FIG. 4 is a perspective view showing yet another embodiment
of a decorative wire mesh embedded in glass, plastic, or other
preferably relatively clear materials, in accord with the present
invention;
[0050] FIG. 5 is a perspective view showing another embodiment of a
decorative wire mesh embedded in glass, plastic, or other
preferably relatively clear materials, in accord with the present
invention;
[0051] FIG. 6 is a perspective view showing use of a first
cross-sectional shaped filament, in this case a twisted planar
surfaced filament, with a second different cross-sectional shaped
filament, in this case a round filament, which may be used in the
decorative wire mesh, in accord with the present invention;
[0052] FIG. 7 is an elevational view, in cross-section, showing a
plurality of cross-sections of some different types of wire
filaments for use in the decorative wire mesh, in accord with the
present invention;
[0053] FIG. 8 is an elevational view, in cross-section, showing
another embodiment of a decorative wire mesh embedded in glass,
plastic, or other preferably relatively clear materials, in accord
with the present invention;
[0054] FIG. 9 is an elevational view, partially in cross-section,
showing a welded mesh structure embedded in glass, plastic, or
other preferably relatively clear materials, in accord with the
present invention;
[0055] FIG. 10 is an elevational view showing a shaped decorative
wire mesh, in this case a circle, embedded in glass, plastic, or
other preferably relatively clear materials, in accord with the
present invention;
[0056] FIG. 11 is an elevational view showing a decorative wire
mesh embedded in clear glass or plastic with a cut out shape, in
this case a circle, in accord with the present invention;
[0057] FIG. 12 is an elevational view showing a decorative wire
mesh figurine, in this case a frog, embedded in glass or plastic,
in accord with the present invention;
[0058] FIG. 13 is a perspective view of a glass-top table using
decorative wire mesh embedded in the clear glass or plastic top, in
accord with the present invention;
[0059] FIG. 14 is an elevational view showing another embodiment of
a decorative wire mesh embedded in clear glass or plastic used as a
wall or divider, in accord with the present invention;
[0060] FIG. 15 is a perspective exploded view of components
utilized to form one possible embodiment of a decorative wire mesh
panel in accord with the present invention;
[0061] FIG. 16 is an elevational view, in cross-section, which
shows the embodiment of a decorative wire mesh panel shown in FIG.
15 after assembly in accord with the present invention; and
[0062] FIG. 17 is an elevational view showing an embodiment of a
wire mesh panel which comprises a mesh with flat wires wherein some
of the flat wires are twisted at specific locations in accord with
one possible embodiment of the present invention.
[0063] While the present invention will be described in connection
with presently preferred embodiments, it will be understood that it
is not intended to limit the invention to those embodiments. On the
contrary, it is intended to cover all alternatives, modifications,
and equivalents included within the spirit of the invention.
GENERAL DESCRIPTION OF PREFERRED EMBODIMENTS FOR CARRYING OUT THE
INVENTION
[0064] Referring now to the drawings and, more particularly to FIG.
1, FIG. 2, and FIG. 3, there is shown wire mesh panel 10 which
comprises wire meshes 12A and 12B which are mounted within upper
transparent panel 14 and lower transparent panel 16. The wire mesh
utilized in wire mesh panel 10 may comprise many different types,
including many different weaves, knits, and constructions. Wire
mesh panel 10 is generally designed to have much less open area
than prior art safety glass and may typically have open area in the
range from zero to eighty-five percent as compared to the total
area of the wire mesh but could comprise other ranges e.g., less
than forty percent. In fact, in some cases it may be desirable to
provide wire mesh with very small open areas or to completely close
off the open areas thereby blocking vision therethrough such as for
a show enclosure or dressing room curtain. Architect may be able to
select a panel based on light passing through, light reflected,
light absorbed, light scattered back or diffused when passing
through panel 10. Thus, an architect may initially select such
factors in order to choose a desired panel.
[0065] Typically, the open area will be less than about fifty
percent of the total area of the wire mesh but could be a smaller
or larger percentage. The reflectance of the wire mesh is also
controlled. Different sides of the wire mesh panel may have
different amounts of reflectivity. A preferred range of reflectance
ranges from total reflectance of the light, up to one hundred
percent to a smaller amount of reflectance such as about fifteen
percent.
[0066] The wire mesh is preferably selected not only for strength
but also for aesthetic purposes. Accordingly, one possible object
of the invention is not necessarily to enhance vision through wire
mesh panel 10 but instead to provide a generally very strong and
aesthetically pleasing construction panel that may be utilized for
a wide variety of construction purposes such as in furniture,
building walls, and the like. The wire diameters may have a fairly
wide range of diameters such as between 0.02 mm to 2 mm or larger.
As the diameter decreases, additional wire strands are utilized to
keep the open areas smaller. The wires may be of any type such as
copper or stainless alloys or any suitable wire with any type of
finish. In one embodiment, due to the limited open areas, most of
the light striking panel, will be reflected and/or absorbed.
[0067] In another embodiment, the wire mesh panel is suitable for
use in hygienic environments. For instance, screens may presently
be provided in hygienic environments such as restaurants,
hospitals, and the like which are difficult to clean. The present
invention provides an easily cleanable panel with the aesthetic
appeal providing by a screen.
[0068] In FIG. 1-FIG. 3, wire mesh 12A is woven with planar
surfaced members such as filaments, wires or the like. However,
other types of wires or combinations of different types of wires
could also be utilized. The wires may or may not comprise insulated
wires, which could be colored, although in a preferred embodiment,
non-insulated wires are utilized. The wire mesh may also employ
numerous different weaves, openings, and constructions only a few
of which are shown herein. As used herein, terms such as filaments,
wires, and/or other planar members comprise terminology that may be
utilized substantially interchangeably. The weaves affect the light
passing through as well as how much light is reflected and how that
light reflects, e.g., by scattering or diffusing the light over the
entire room.
[0069] Preferably transparent or translucent panels 14 and 16 are
made of any suitable material such as glass, plastic, lexan,
polycarbonates, acrylics, any suitable materials discussed
hereinbefore, or any other suitable relatively clear or translucent
material such that the wire mesh is visible through the panels.
Translucent panels 14 and 16 may be rigid but could also be
flexible to a certain extent so that panel 10 may be bendable by a
certain amount. For a rigid construction either the translucent
panels or the mesh may be rigidly formed. Considerations for panels
14 and 16 may also include insulation properties, clarity, any
tinting, tensile strength, and so forth. A single translucent panel
may also be utilized wherein the mesh is encapsulated such as by
melting into the glass whereby the result is a wall like structure
with a relatively large surface area with length and height much
larger than the thickness of the panel.
[0070] The panels may be designed to provide a selected amount of
light to be passed through or reflected such that an architect can
make a panel selection based on such considerations. Thus, an
architect will be able to design the amount of light coming through
the screen such as through skylights, window panels, or the like.
Various factors can be controlled in the construction of wire
screen to control reflectance, light scattering, and translucence
or the amount of light passing through the screen. Such control
techniques may comprise selecting one or more of factors such as
the wire mesh weave, selecting twists in wires to control
reflectance, selecting a percentage of open regions of the wire
mesh to affect both reflectance and translucence, selecting one or
more cross-sectional shapes for a first plurality of wires and a
second plurality of wires which may be woven together, selecting a
diameter of the first plurality of wires and the second plurality
of wires, selecting a texture of the first plurality of wires and
the second plurality of wires and/or selecting a reflectance,
gloss, polish, or the like, of the first plurality of wires and the
second plurality of wires
[0071] In one preferred embodiment, the wire mesh is bonded,
epoxied, glued, or the like between panels 14 and 16 and/or other
panels as indicated in FIG. 3 utilizing clear adhesive material 18
which may be inserted into the interstices, openings, cracks,
and/or gaps between panels 14 and 16 within the wire mesh, such as
wire mesh 12B.
[0072] Wire meshes 12A and 12B in FIG. 1 and FIG. 2 utilize planar
surfaced members such as wires 20A;20B, 22A;22B, 24A;24B, and
26A;26B in a first direction, which may comprise parallel shute
filaments. The cross-directional planar surface members or
filaments, such as circular cross-section wires 28A;28B, 30A;30B,
32A;32B, 34A;34B, are woven transverse to the first direction, and
may be the parallel warp filaments. In a preferred embodiment, the
wires or filaments in one direction will be substantially
identical, but depending on the equipment utilized for weaving, may
not always be so. Generally, warp filaments are those that go along
the length of the weave and shute filaments are those that go
sideways with respect to the length of the weave. However, the mesh
may also be knitted, such as a scrubbing mesh, or welded, or
stamped. The welding of a mesh may be utilized to stiffen the mesh
or rigid straight wires could be utilized to form a framework that
is welded together. Knitted generally refers to stitching
techniques which uses two or more knitting needles to make a wire
fabric. Stamping may include insertion of a stamping tool to make
an opening and then widening the opening.
[0073] The warp wires and the shute wires may or may not be
identical and may have different types of cross-sections as shown
in FIG. 4 and FIG. 5. In FIG. 4, wire mesh panel 10 comprises wire
mesh 12C, which is woven with different cross-sectional types of
planar surfaced wires. While in FIG. 5, the wires are of the same
type.
[0074] Note that the wires may have much smaller diameters. For
instance each warp member 36D, 38D and shute member 40D, 42D might
comprise many separate smaller diameter wires. Thus, for instance,
36D may comprise many individual smaller wires which may be unwoven
and aligned parallel to each other or which may be woven together
to form 36D. Any cross-sectional type of wire may be utilized
herein, as indicated in FIG. 7, which shows several different
cross-section types of wires including planar wire 44 which may be
flat with round corners and/or oval, triangular wire 46, square
wire 48, rectangular wire 50 and round wire 52. Many other types of
wires could also be utilized. As shown in FIG. 6, wires of
different types such as round wires 52 and rectangular wires 54 may
be utilized therein. As indicated in FIG. 6, rectangular
cross-section wire may twisted, perhaps randomly or regularly
twisted in a mesh, to thereby affect not only the visual effect of
the mesh but also the reflectance of the mesh and the diffusion of
light reflected and passed by the mesh through panel 10.
[0075] Thus, wire mesh panel 10 could be woven with a combination
planar and non-planar cross-sectional type members or filaments and
with a wide range of different diameter wires. For instance, planar
wires, or wires laid together or woven together to form planar
members, may be woven with round cross-sectioned wires or wires
laid together or woven together to form round members. Planar wires
or wires laid to form planar patterns or members may also be woven
with different cross-sectioned planar wires or wires laid in planar
fashion to form other members, e.g., rectangular cross-sectioned
planar wires or members with triangular cross-section planar wires
or members.
[0076] Referring to intersections 54D, 56D, and 58D in FIG. 5, it
will be noted that in a preferred embodiment the wires intersect
but do loop around each other. Due to the inherent strength of a
mesh with smaller open areas, which may be the result of more wires
and/or larger diameter wires, there is no need to wrap or twist the
wires completely around each other as per prior art wire mesh
safety glass. Thus, the wires typically engage each other, and may
slidingly engage each other unless the wire mesh is epoxied or
otherwise adhered into position. It will also be noted that in FIG.
5 the open areas of the mesh, such as openings 60, 62, and 64,
provide about ten to thirty percent open area as compared to the
overall area of the mesh.
[0077] In another embodiment of the invention, planar surface wires
such as planar surface wires 36D, 38D, 40D, and 42D in FIG. 5 may
be utilized to reduce the overall thickness of mesh 12D, and thus
the overall thickness of panel 10. For some types of weaves, the
variations produced by the intersections are greatly reduced by
reducing the height of intersections to the extent that one side of
the weave may effectively have no knuckles or portions extending
outwardly from an average height of the mesh. Thus, light reflected
may be less diffused when utilizing such weaves. For instance,
referring to FIG. 3, it can be seen that on the upper side of mesh
12B adjacent panel 14, the mesh is substantially flat with no
knuckles. Other meshes, may utilize, for instance, a five-heddle
weave to thereby effectively eliminate the knuckles on one side and
also reduce the number of crossing intersections that could produce
knuckles. Use of weaves with significant knuckles results in a
greater amount of diffusing of the reflected light. Other heddle
weaves could also be utilized with more or fewer intersections per
row. For instance, intersections where the wires change levels in a
row could be spaced by every 2nd-4th planar element in a heddle
weave. As another example, the reduced diameter knuckles could be
spaced apart by more than five elements or filaments in a heddle
weave, and may effectively result in zero knuckles. Wire mesh 12B
of FIG. 3 shows a three-heddle weave. Other types of suitable
weaves, a few possibilities of which are shown herein, include
twill, plain, Dutch weave, twill weave, lock crimped, ride
lockcrimped or flat top, weaving combinations, other weaves, and so
forth. FIG. 8 shows a five-heddle weave with relatively flat
surfaces on either side of mesh 12E.
[0078] In yet another embodiment, the wire mesh may utilize wires
that are welded at each intersection to provide additional
strength, such as shown in the cross-sectional view of FIG. 9.
Thus, wires 66 and 68 are welded at intersections 70 and 72 to wire
74 in wire mesh 12F. FIG. 9 also illustrates that, if desired,
fasteners such as fasteners 76 and 78 may be utilized for securing
panels 14 and 16 together with mesh 12F. Many different types of
fasteners could be utilized, as desired. Note that epoxy may or may
not be utilized in interstices 18 when fasteners are utilized.
[0079] FIG. 10-12 show variations of use of mesh in panels 10. In
FIG. 10 circular mesh 12G is utilized. In FIG. 11, mesh 12H
provides for port hole 80. In FIG. 12, mesh 12I is in the form of
an animal, design, or other arbitrary shape. If desired, in FIG.
10, the center region may be provided as only a screen and with no
translucent covering. Thus, panel shown in FIG. 10 may provide a
working screen that is mounted in the same way as a panel of glass
to thereby avoid the special construction requirements for
replacing glass with a screen or for mounting a screen. The center
screen could also be utilized as an easily mountable filter for
filtering particles such as in a filtering system. Screens mounted
in glass may also be utilized with special screens, e.g.,
interferometer screens, for use in scientific instruments.
[0080] Panel 10 effectively forms construction material that can be
utilized in a wide variety of ways. For instance in FIG. 13, panel
10 is mounted as the top in a coffee table or other table 82. Panel
10 may be provided as a counter in a bar or as a counter top for a
kitchen. In FIG. 14, multiple panels 10 are mounted together to
form a wall 84, such as the wall in an office building, bank,
divider walls, shower doors, fireplace glass, balconies, stairs,
skylights, or the like.
[0081] One possible preferred embodiment panel 100 is shown in
exploded form in FIG. 15 and in cross-section in FIG. 16. In FIG.
15, glass-like materials such as glass, polycarbonates, plastics or
other suitable materials, some of which have been listed and/or
referenced hereinbefore, may preferably be utilized for outer panel
layers 102 and 104. Layers 102 and 104 may also comprise tempered
glass, annealed glass, heat strengthened glass, as desired. Layers
102 and 104 may be transparent or translucent with colors,
patterns, particles embedded therein, or the like, as desired.
[0082] Layers 102 and 104 may comprise different materials. For
instance, layer 102 may comprise glass and layer 104 may comprise
polycarbonate. Moreover, additional layers such as glass layers,
plastic layers, and polycarbonate layers, with additional inner
layers therebetween may be utilized, e.g. glass, polyvinyl butyral,
glass, polyvinyl butyral, glass, urethane, polycarbonate.
Accordingly, the example of FIG. 15 is merely one possibility of
construction and numerous different types of layers may be utilized
in accord with the present invention.
[0083] The use of wire mesh 110 therewith opens the possibility for
greatly increasing the strength of panel 110 to provide blast
resistant, hurricane impact resistant, bullet resistant,
forced-entry resistant, or simply decorative panels that are
aesthetic and attractive. In one preferred embodiment, panels such
as panel 110 may be easily mounted in a similar manner as one might
mount panes of glass into a window frame.
[0084] Plastic, films, resins, vinyls, urethanes, polyvinyl
butyral, PVB, EVA, and/or other suitable materials some of which
have been listed hereinbefore, may be utilized inside of outer
panel layers 102 and 104 to form one or more inner layers of
materials which bind outer layers 102 and 104 together with mesh
110. In the embodiment shown in FIG. 15, two inner layers 106 and
108 are utilized which may be heated, and/or melted, and/or
compressed and/or cooled to thereby bond together the components of
panel 100. However, more or less than two inner layers may be
utilized as desired, or as most expedient. The inner layers may
preferably have sufficient volume to fill in the open areas of wire
mesh 110 which may preferably be utilized in a central portion such
that, if desired, no air gaps are introduced therein. In one
preferred embodiment, the outer glass layers are compressed and
heated to a temperature which may preferably be less than about one
thousand degrees centigrade to thereby melt the materials of 106
and 108. Other materials for inner layers 106 and 108 discussed
below may require different treatment. Layers 106 and 108 may be
different materials which may interact or mix together or may
comprise the same material. Layers 106 and 108 may effectively be
one layer and/or effectively be one continuously bound layer with
mesh 110 therebetween.
[0085] One embodiment of a method for making a panel in accord with
the invention comprises steps such as compressing and heating
layers 106 and 108 whereby the openings in mesh 110 are filled and
the outer layers 102 and 104 are secured together. In this way,
panel 100 becomes a solid, high-strength construction as shown in
cross-section in FIG. 16. As discussed above, layers 106 and 108 as
shown in FIG. 16 may be formed by one or more layers of plastic and
or other materials that are preferably melted to thereby bond with
outer layers 102 and 104 as well as mesh 1110. FIG. 16 shows a
preferred cross-section, but additional layers may be utilized
within panel 100 as desired.
[0086] As another possible example, PVB foils may be utilized for
layers 106 and 108. PVB foils, in one embodiment, may be best
utilized during manufacturing in a climate regulated atmosphere.
One possible type of suitable PVB foil is sold under the name
Trosifol. Trosifol foil can be used for manufacturing panel 100
simply with a vacuum bag and without the need for heat from using,
for instance, an autoclave. However, with normal PVB foils, panel
100 may be formed by being put into an oven or autoclave and heated
ninety to one hundred forty degrees Centigrade wherein pressure and
heat are applied. PVB laminated glasses have good sound deadening
and are generally considered to be rated as safety glass as may be
especially desirable for use in stairways and/or other constructive
glass applications.
[0087] As another possible example, EVA foil may be utilized which
may be utilized for manufacture of panels 100 without the need for
larger equipment. Generally, foils such as PVB or EVA, may be
utilized as layers 106 and 108 which surround mesh 110, and which
are utilized between glass layers 102 and 104. In order to pull out
the air between the foils and the mesh, the whole construction 100
may be placed into a vacuum bag. The vacuum bag under constant
vacuum is placed into an oven and heated at the desired
temperature. Utilizing normal PVB, an autoclave is utilized to
produce heat and pressure as necessary.
[0088] FIG. 17 discloses a translucent and/or transparent panel 100
through which one can observe a novel wire mesh 110 mounted therein
which may be effectively utilized architecturally for reflecting,
directing, and/or diffusing light. In one possible embodiment, mesh
110 comprises flat, substantially flat, or planar surfaced wires
for both shute wires 112 and the warp wires 114. Flat or
substantially flat wires, as referred to herein, have two surfaces
with a flat or substantially flat appearance as seen when looking
at transparent panel 100, such as might be described by
cross-sections 44, 48, and 50 as shown in FIG. 7, wherein the
cross-sections may be taken at various points along the length the
wire and where, in a preferred embodiment, the cross-sections so
taken remain substantially constant. However, it will be understood
that other types of wires besides flat wires may also be used in
the mesh.
[0089] For visual effects where twisting of wires may be used in
accord with one embodiment of the invention, the twist is more
visible if the wires utilized comprise a cross-section such that
twisting produces a visually perceptible change, e.g., a twist in a
wire with a rectangular cross-section as compared to a twist in a
perfectly round cross-section which may not be readily
discernible.
[0090] Variations of the flat wires in mesh 110 can be readily
selected to produce desired architectural effects. Such variations
of the flat wires to produce desired architectural effects include
but are not limited to variations in width, opening spaces,
reflectance, type of metal or alloy, finish of the metal, type of
weave, and/or other variations disclosed hereinbefore, and/or the
number and spacing of twists as discussed hereinafter.
[0091] Twists in warp and shute wires 112 and 114, such as twists
116 and 118, and the like, may be inserted at random positions, at
irregular positions, and/or in a pre-determined pattern, as
discussed hereinbefore. In one possible preferred embodiment, the
twists are produced within particular portions of the wire rather
than spread along the length of the wire. Each twist may involve at
least one-half turn of the wire but could utilize one or more
complete turns and each twist may have a preset, random, or
irregular numbers of turns. The twists may be positioned anywhere
in the weave including at the intersections, between the
intersections, at either side of the mesh, at any specified or
regular positions, at irregular, random, and/or regular spacings
between twists and/or intersections and/or positions within the
mesh, and/or at some combination of the above factors or other
desired factors. As a general rule, while the shute or warp wire
may be twisting, the shute and warp wires are not twisted together
to form an intersection, although if desired they could be.
[0092] The spacing, number, location, and other various features of
the twists may be selected based on the type and/or amount of
lighting, reflection, or other visual effects which may be desired.
The visual effects of wire mesh panels in accord with the present
invention are discussed hereinbefore.
[0093] The weave may be a particular pattern, an irregular pattern,
and/or a random pattern, as desired. If twists are desired, the
twists may be positioned only in shute wires or only in warp wires
or both. FIG. 17 provides an example where twists, such as twist
116 and 118 are included in both the shute and warp wires. The warp
and shute wires may be substantially straight or may contain
random, regular, or irregular curves as desired. As discussed
above, while binding layers such as layers 106 and 108 may be
utilized, resins may also be utilized. Resins may often be utilized
more easily with larger wire diameters and smaller quantities of
product produced.
[0094] It will be understood that terms such as wire mesh, woven or
knitted mesh, and the like are often used interchangeably herein.
By planar members it is meant herein that at least one surface of
the wire, member, or filament substantially comprises a plane, has
a cross-section which appears to provide a relatively flat
continuous, smooth surface, or at least has a variable shape so
that one portion of the cross-section is readily visually
distinguishable from another portion. The cross-sectional shape may
be substantially constant even if the wire itself is not exactly
horizontal or straight but instead follows the weave of the mesh
and if the wire includes turns or twists. In one preferred
embodiment, the shape of the cross-section will preferably be
continuous along the length of the member, filament, or wire. Thus,
calendaring an already woven screen will not produce planar members
with continuous, regular surfaces as discussed herein, because
calendared filaments or wires do not have substantially the same
cross-section along their length. Instead, calendaring will produce
variations in the cross-sections of the wires or filaments at the
knuckles. However, calendared screens may also be utilized in
accord with the present invention.
[0095] Moreover, the woven planar filament meshes of the present
invention may be molded into other shapes, which may not be
relatively or perfectly flat, or which may be pleated or rounded,
and/or may be utilized in any desirable shape within any type of
filtration equipment which may not utilize vibration but may also
utilize pressure or other means of filtration. It will be
understood from review of the disclosure of the present invention
that many different types of weaves and combinations utilizing
woven planar members in accord with the present invention may be
utilized.
[0096] The woven planar wires may comprise fibers of various types,
stainless steel, carbon steel, other visually pleasing metallic
materials, combinations thereof, colered plastic, or any other
suitable material. A screen in accord with one possible embodiment
of the present invention is preferably woven. One additional
advantage of woven screens is a built-in resistance against
vibration and the strength thereof as may be desirable for certain
construction projects.
[0097] In one possible embodiment, woven wires such as wires 112
and 114 may comprise diameters of 0.5 millimeters or less, if
desired, and may be woven in rolls with decorative aspects such as
comprising various metals with various colors. As noted above, in
one preferred embodiment, the wires are flat to thereby provide
reflection visual effects. As already noted above, other visually
effective meshes may include herring bone meshes and the like. In
another embodiment, smaller wires in the range of 0.025 mm or so in
100 mesh mesh may be utilized to produce visually pleasing and/or
practical screens, e.g., radar antennas.
[0098] Thus, the foregoing disclosure and description of the
invention is therefore illustrative and explanatory of one or more
presently preferred embodiments of the invention and variations
thereof, and it will be appreciated by those skilled in the art
that various changes in the design, organization, order of
operation, means of operation, equipment structures and location,
methodology, and use of mechanical equivalents, as well as in the
details of the illustrated construction or combinations of features
of the various elements, may be made without departing from the
spirit of the invention. As well, the drawings are intended to
describe the concepts of the invention so that the presently
preferred embodiments of the invention will be plainly disclosed to
one of skill in the art but are not intended to be
manufacturing-level drawings or renditions of final products and
may include simplified conceptual views as desired for easier and
quicker understanding or explanation of the invention. It will be
seen that various changes and alternatives may be used that are
contained within the spirit of the invention. Moreover, it will be
understood that various directions such as "upper," "lower,"
"bottom," "top," "left," "right," "inwardly," "outwardly," and so
forth are made only with respect to easier explanation in
conjunction with the drawings and that the components may be
oriented differently, for instance, during transportation and
manufacturing as well as operation. Because many varying and
different embodiments may be made within the scope of the inventive
concept(s) herein taught, and because many modifications may be
made in the embodiment herein detailed in accordance with the
descriptive requirements of the law, it is to be understood that
the details herein are to be interpreted as illustrative and not in
a limiting sense.
* * * * *