U.S. patent application number 15/025220 was filed with the patent office on 2016-08-18 for milanese mesh rolling.
The applicant listed for this patent is APPLE INC.. Invention is credited to Justin T. Sawyer.
Application Number | 20160236263 15/025220 |
Document ID | / |
Family ID | 49382596 |
Filed Date | 2016-08-18 |
United States Patent
Application |
20160236263 |
Kind Code |
A1 |
Sawyer; Justin T. |
August 18, 2016 |
MILANESE MESH ROLLING
Abstract
A flexible Milanese mesh material is disclosed herein.
Particularly, the Milanese mesh material may have a structure that
is conducive to a more flexible mesh material. The Milanese mesh
may be formed from rows of wire spirals having a flexibility
improving cross-section. The flexibility of the Milanese mesh may
be improved by applying a secondary finishing process to the
Milanese mesh. The finishing process may include continuously
rolling the Milanese mesh around and/or against a mandrel such that
the Milanese mesh product forms a smaller loop around the mandrel
as the flexibility of the Milanese mesh product improves.
Inventors: |
Sawyer; Justin T.;
(Cupertino, CA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
APPLE INC. |
Cupertino |
CA |
US |
|
|
Family ID: |
49382596 |
Appl. No.: |
15/025220 |
Filed: |
September 30, 2013 |
PCT Filed: |
September 30, 2013 |
PCT NO: |
PCT/US2013/062625 |
371 Date: |
March 25, 2016 |
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
B21F 43/00 20130101;
A44C 27/002 20130101; B21F 15/04 20130101; A44C 5/0061
20130101 |
International
Class: |
B21F 15/04 20060101
B21F015/04; A44C 27/00 20060101 A44C027/00; B21F 43/00 20060101
B21F043/00 |
Claims
1. A mesh carpet comprising a first wire coil having a
cross-section defined by a first surface and a second surface which
oppose one another, with the first surface and the second surface
connected by a transition surface; and a second wire coil threaded
into the first wire coil such that the first surface contacts a
second wire coil surface; wherein the first wire coil and the
second wire coil form two rows of the mesh carpet.
2. The mesh carpet of claim 1, wherein the first surface and the
second surface are opposing flat surfaces positioned at an acute
angle from one another.
3. The mesh carpet of claim 1, wherein the first surface and the
second surface are opposing flat surfaces positioned at an obtuse
angle from one another.
4. The mesh carpet of claim 1, wherein the first surface and the
second surface are concave surfaces with the concave surfaces
having a profile that approximately matches the second wire coil
surface.
5. The mesh carpet of claim 1, wherein: the first surface and the
second surface are opposing flat surfaces positioned at an angle to
one another; and a first side of the first surface and a first side
of the second surface are connected by a first arc that is a
portion of the cross-section of the wire that is proximal to the
coil axis.
6. The mesh carpet of claim 5, wherein: the transition surface is
an arc; a second side of the first surface and a second side of the
second surface are connected by a transition surface that is a
second arc; and the second arc is longer than the first arc.
7. A method of forming a mesh carpet comprising: obtaining a first
coiled wire having a cross-section defined by a first surface and a
second surface which oppose one another, with the first surface and
the second surface connected by a transition surface; obtaining a
second coiled wire; intertwining the second wire into the first
wire to form a mesh carpet; and contacting the first surface with
the second coiled wire.
8. The method of claim 7, wherein the first surface and the second
surface are opposing flat surfaces positioned at an angle to one
another.
9. The method of claim 7, wherein the first surface and the second
surface are concave surfaces having a profile that approximately
matches the second wire coil surface.
10. The method of claim 8, wherein the operation of intertwining is
accomplished by contacting the first surface with a first exterior
convex surface of the second wire.
11. The method of claim 9, wherein the operation of intertwining is
accomplished by contacting the first concave surface with a first
exterior convex surface of the second wire.
12. The method of claim 7, further comprising obtaining a third
wire and intertwining the third wire into the second wire.
13. A method of improving the flexibility of a mesh carpet
comprising: constraining a first end of the mesh carpet in a
restraint; constraining a second end of the mesh carpet in a
movable restraint; wrapping the mesh carpet around a first mandrel
having a circumference smaller than natural mesh flexibility
circumference; and continuously moving the mesh carpet around the
first mandrel, thereby forming a smaller mesh flexibility
circumference without the mesh carpet being impacted by the first
mandrel or additional mandrels.
14. The method of claim 13, wherein, as the mesh carpet
continuously moves around the first mandrel, the first mandrel
rotates such that the mesh carpet and any points of contact between
the mesh carpet and the first mandrel are substantially stationary
relative to one another, thereby preventing the mesh carpet from
sliding across the circumference of the first mandrel.
15. The method of claim 14, further comprising: moving the first
mandrel away from a first end of the mesh carpet that is in a fixed
restraint until a substantial portion of the mesh carpet has moved
around the first mandrel; and moving the second end of the mesh
carpet that is in a movable restraint in the opposite direction,
thereby causing the first mandrel and the mesh carpet to move back
around the first mandrel in the opposite direction until the first
mandrel has returned to an original location.
16. The method of claim 15, further comprising locating the mesh
carpet between a first restraint plate and a second restraint plate
as the mesh carpet is moved around the first mandrel.
17. The method of claim 16, further comprising: contacting the mesh
carpet with the first restraint plate; and moving the first
restraint plate closer to the second restraint plate after a
substantial portion of the mesh carpet has moved around the first
mandrel at least once, thereby causing the circumference of the
mesh carpet to be compressed between the first restraint plate and
the second restraint plate.
18. The method of claim 13, further comprising moving the mesh
carpet to a smaller mandrel after a substantial portion of the mesh
carpet has moved around the first mandrel.
19. The method of claim 18 wherein as the mesh carpet continuously
moves around the mandrel, the mandrel is stationary causing the
mesh carpet to slide across the circumference of the mandrel.
20. The method of claim 13, further comprising: wrapping the mesh
carpet around a second mandrel and a third mandrel such that the
mesh carpet occupies a zigzag pattern across the first mandrel,
second mandrel, and third mandrel; and driving the mesh carpet back
and forth through the path of the first mandrel, second mandrel,
and third mandrel.
21. An apparatus for improving the flexibility of a mesh carpet,
comprising: a first mandrel having a circumference smaller than
natural mesh flexibility circumference; a first restraint attached
to the first end of the mesh carpet; a second restraint attached to
the second end of the mesh carpet and the second restraint is
located relative to the first restraint such that the mesh carpet
wraps around the first mandrel.
22. The method of claim 21, wherein: the first mandrel rotates such
that as the mesh carpet moves around the first mandrel the mesh
carpet; and all points of contact between the mesh carpet and the
first mandrel are substantially stationary relative to one another,
thereby limiting the mesh carpet from sliding across the
circumference of the first mandrel.
23. The method of claim 22, wherein: the first restraint is a fixed
restraint; the second restraint is a movable restraint; the first
mandrel is movable laterally such that, in response to the mandrel
moving, the mesh carpet is pulled around the mandrel by a static
force from the first restraint; and the second restraint is
configured to receive a force that moves the mesh carpet and the
mandrel back to an original position.
24. The method of claim 23, further comprising a first restraint
plate and a second restraint plate, the mesh carpet and the first
mandrel located between the first restraint plate and the second
restraint plate.
25. The method of claim 23, wherein: the first restraint plate
contacts the mesh carpet and is configured to be movable relative
to the second restraint plate, thereby allowing the gap between the
first restraint plate and the second restraint plate to decrease as
the circumference of the mesh carpet decreases.
27. The method of claim 21, wherein the first mandrel is stationary
causing the mesh carpet to slide across the circumference of the
mandrel.
28. The method of claim 21, further comprising a second mandrel and
a third mandrel positioned relative to one another such that the
mesh carpet forms a zigzag pattern as the mesh carpet is wrapped
around the first mandrel, second mandrel, and third mandrel.
Description
TECHNICAL FIELD
[0001] This disclosure relates generally to a wire mesh, and more
particularly to a Milanese wire mesh and individual wire coils
which provide a highly flexible mesh carpet, and methods and
apparatuses for manufacturing the same.
BACKGROUND
[0002] A Milanese mesh structure (sometimes called a "carpet"), as
illustrated for example in FIG. 1A, is a decorative mesh typically
made from multiple metallic spiral wires threaded together. The
wire utilized in forming the spirals, as illustrated for example in
FIG. 1B. typically has a circular cross-section as illustrated, for
example, in FIG. 1C. The mesh carpet is sometimes used to make
necklaces, bracelets, or other decorative accessories.
[0003] Typically, a spool containing a straight wire material is
set into a machine, The machine runs the wire material into a
mandrel apparatus that forms the wire material into a spiral. The
spiral is then forced forward and cut off at a certain length.
After this, the machine makes the next spiral. This new spiral is
then threaded into an already existing cutoff spiral. Once threaded
the machine cuts off the new spiral. This process is continually
repeated until a mesh carpet is formed.
[0004] Once the mesh carpet is formed, it is cut into various
shapes depending on the end product. Typically, the product is
formed of relatively short pieces of mesh. The pieces of mesh may
be manually bound into a long strip utilizing another spiral of
equal strength to join the discrete pieces together. The edges may
then be processed to remove sharp and uneven coil ends. In this
form the mesh is unstable as the individual coils can be removed.
As such, the material may be locked so that the individual coils
movement is significantly limited and the mesh carpet is secure.
The locking is accomplished by pressing the strip flat and thus
deforming the shape of the round coils.
[0005] Once locked, the mesh may be further processed to provide
flexibility. The mesh may pass through a machine with cylinders
that oscillate or otherwise move up and down, thereby forcing the
mesh strip to bend back and forth. This treatment makes the mesh
flexible but also often leaves visible lines in the mesh from
contact with the internal cylinders of the machine.
[0006] Other processing steps may be used to improve the overall
aesthetics of the mesh. For example, a folding clasp and/or end
pieces may be formed by stamping the ends. The mesh strips may also
undergo a polishing to enhance their appearance.
[0007] Typical manufacturing process for Milanese mesh devices do
not allow mesh carpets that are created to be flexible without the
crimping of the mesh and or introduction of the intervening binding
and locking coils discussed above. Thus, there is a need for a
improved method for forming a Milanese mesh product.
SUMMARY
[0008] Generally, embodiments disclosed herein may include
apparatuses and methods for forming a flexible mesh carpet. The
mesh carpet may be made flexible in a variety of ways. For example,
the coils of the mesh carpet may be preformed to have a particular
cross-section in order to manufacture a flexible mesh carpet. In
another example, the mesh carpet may be processed after manufacture
in order to improve the flexibility. Additionally the various
examples may be combined to achieve greater flexibility, e.g. a
mesh carpet made from preformed coils may undergo additional
processing to further improve the flexibility. In the various
embodiments and examples the mesh carpet may be a Milanese mesh
carpet.
[0009] In one embodiment, a flexible mesh carpet may include a
first wire coil. The first wire which makes up the coil may have a
first surface and a second surface which oppose one another. The
first surface and the second surface may be connected by surfaces
that substantially form partial arcs (e.g. of a circle or
ellipsis). The mesh carpet may also include a second wire coil
threaded into the first wire coil. One of the surfaces from the
first wire coil may contact a surface on the second wire coil. The
first wire coil and the second wire coil may form two rows of the
mesh carpet. In one example, the first surface and the second
surface in the first wire coil may be opposing flat surfaces
positioned at an acute angle from one another. Alternatively they
may be positioned at an obtuse angle from one another. In another
example, the first surface and the second surface may be concave
surfaces. The concave surfaces may have a profile that
approximately matches the second wire coil surface. In another
example, the wire may have a triangular cross-section. In such and
example, the first surface and the second surface may be opposing
flat surfaces positioned at an angle to one another connected by
another flat surface.
[0010] In another embodiment, the flexibility of a mesh carpet may
be improved by wrapping the mesh carpet around a first mandrel
having a circumference smaller than natural mesh flexibility
circumference of the mesh carpet. The first end of the mesh carpet
may be constrained in a fixed or moveable restraint. The second end
of the mesh carpet may be constrained in a movable restraint. The
mesh carpet may then be moved back and forth around the first
mandrel forming a smaller mesh flexibility circumference without
the mesh carpet being impacted by the first mandrel or additional
mandrels, The finishing process may include continuously rolling
the Milanese mesh around or against the mandrel such that the
Milanese mesh carpet forms a smaller loop around the mandrel as the
flexibility of the Milanese mesh product improves.
[0011] The finishing process may include compressing the mesh
carpet between two restraining plates such that the restraining
plates contact the mesh carpet decreasing the bend radius and
thereby improving the flexibility of the mesh carpet. Another
embodiment may take the form of utilizing a coil with a specific
wire cross-section and providing a secondary finishing process to
the mesh carpet. The mesh carpet may be moved to a smaller mandrel
after a substantial portion of the mesh carpet has moved around the
first mandrel.
[0012] In accordance with one embodiment, the mesh carpet may be
wrapped around a first mandrel. Contact may be made between the
mesh carpet and the first mandrel. The mesh carpet may be moved
back and forth across the mandrel. The mesh carpet may be moved to
a smaller mandrel. The mesh carpet may be moved back and forth
across the smaller mandrel. This may continue to subsequent
mandrels such as a third or fourth mandrel. The method may end once
an improved or desired flexibility is achieved in the mesh
carpet.
[0013] In accordance with one embodiment, a mesh carpet may be
wrapped around a first mandrel. Contact may be made or maintained
between the mesh carpet and the first mandrel. The mesh carpet may
be wrapped around a second mandrel. The mesh carpet may also be
additionally wrapped around other mandrels such as third mandrel
and weaved between them in a zigzag path. The mesh carpet may be
translated in a first direction causing both sides of the mesh
carpet to contact and bend against each of the mandrels. The mesh
carpet may be translated in a second direction in addition to the
first direction. Alternatively the mesh carpet may be continuously
translated in the same direction and not back and forth.
[0014] It is to be understood that both the foregoing general
description and the following detailed description are for purposes
of example and explanation and do not necessarily limit the present
disclosure. The accompanying drawings, which are incorporated in
and constitute a part of the specification, illustrate subject
matter of the disclosure. Together, the descriptions and the
drawings serve to explain the principles of the disclosure.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] FIG. 1A shows an example of a prior art strip of Milanese
mesh.
[0016] FIG. 1B shows an example of an isometric view of a prior art
Milanese mesh wire coil.
[0017] FIG. 1C shows an example of a cross-section view of a prior
art Milanese mesh wire coil.
[0018] FIG. 2A shows an example of an isometric view of Milanese
mesh wire coil with flat surfaces,
[0019] FIG. 2B shows an example of a cross-section view of a
Milanese mesh wire coil with flat surfaces.
[0020] FIG. 3A shows an example of an isometric view of Milanese
mesh wire coil with concave surfaces.
[0021] FIG. 3B shows an example of a cross-section view of a
Milanese mesh wire coil with concave surfaces.
[0022] FIG. 4A shows an example of an isometric view of Milanese
mesh wire coil that is triangular.
[0023] FIG. 4B shows an example of a cross-section view of a
Milanese mesh wire coil that is triangular.
[0024] FIG. 5 is a schematic view of an example of a massaging
machine for improving the flexibility of a mesh carpet as known in
the art.
[0025] FIG. 6 is a schematic view of an example of a system for
improving the flexibility of a mesh carpet.
[0026] FIG. 7A-C is a schematic view of an example of a system for
improving the flexibility of a mesh carpet.
[0027] FIG. 8 is a schematic view of an example of a system for
improving the flexibility of a mesh carpet.
[0028] FIG. 9 is a flow chart illustrating an example method of
improving the flexibility in a mesh carpet utilizing preformed
coils.
[0029] FIG. 10 is a flow chart illustrating an example method of
improving the flexibility in a mesh carpet utilizing restraint
plates.
[0030] FIG. 11 is a flow chart illustrating an example method of
improving the flexibility in a mesh carpet utilizing multiple
mandrels.
[0031] FIG. 12 is a flow chart illustrating an example method of
improving the flexibility in a mesh carpet utilizing offset
mandrels.
DETAILED DESCRIPTION
[0032] Generally, embodiments disclosed herein may take the form of
a flexible mesh carpet and methods for forming the same. In various
embodiments and examples the mesh carpet may be a Milanese mesh
carpet. The mesh carpet may have a structure that is formed by a
flexible mesh material. One embodiment may take the form of a mesh
carpet being formed from rows of preformed coils. The coils may be
pre-formed with a specific cross-section (e.g., shape) of wire that
improves or enhances the flexibility of the mesh carpet. Examples
of cross-sections include wires that have flat sides, concave
sides, or are generally triangular. Certain cross-sections may
allow an improved flexibility in the mesh carpet over a traditional
circular wire cross-section. Utilizing preformed wires may improve
mesh carpet flexibility without requiring a secondary process to
enhance flexibility, for example, by deforming, stretching or
manipulating the constituent wires.
[0033] Another embodiment may take the form of applying a secondary
finishing process to a mesh carpet. The finishing process may
include continuously rolling the Milanese mesh around or against a
mandrel such that the Milanese mesh carpet forms a smaller loop
around the mandrel as the flexibility of the Milanese mesh product
improves. The finishing process may include compressing the mesh
carpet between two restraining plates such that the restraining
plates contact the mesh carpet, decreasing its bend radius, and
thereby improving the flexibility of the mesh carpet. Multiple size
mandrels may be used. Mandrels may also be offset from one another,
allowing both sides of a mesh carpet to be worked simultaneously.
Another embodiment may utilize a coil with a specific wire
cross-sectional shape to form the mesh carpet, and may provide a
secondary finishing process to the mesh carpet.
[0034] As indicated above, a Milanese mesh carpet, shown for
example in FIG. 1A, is a decorative mesh typically made from a
plurality coils with the plurality of coils threaded together. The
wire utilized in coil 110, as illustrated for example in FIG. 1B,
traditionally has a circular cross-section 108 with a single
circumferential exterior surface 106 as illustrated in FIG. 1C.
However, once the Milanese mesh carpet is formed, the circular
cross-section of the wire coils limits the flexibility of the mesh
carpet insofar as the bend radius of the coils is limited. To
improve the flexibility of a mesh carpet when compared to one
formed with circular cross-sectional wire coils, coils with
flexibility improving (e.g., non-circular) cross-sectional shapes
may be utilized. FIGS. 2-4 illustrate examples of these flexibility
improving cross-sections.
[0035] In one embodiment and as illustrated in FIGS. 2A and 2B, a
coil 200 may have a non-circular major exterior surface. The major
exterior surface as shown in FIG. 2B is the perimeter of the
cross-section 201 of wire 200, which may define a plurality of
exterior surfaces. For example, the plurality of exterior surfaces
may include a first flat surface 204 and a second flat surface 208.
As one example, the first flat surface 204 and the second flat
surface 208 may be formed on opposing sides of an axis running
through the cross-section and may taper toward that axis and thus
toward one another
[0036] In various embodiments, the flat surfaces 204/208 may be
positioned relative to one another at one of an acute angle, an
obtuse angle or parallel. The first flat surface 204 and the second
flat surface 208 may be connected by an outward-facing surface 202
("outward surface") and an inward-facing surface 206 ("inward
surface"). It should be appreciated that these outward and inward
orientations are provided with respect to an axis running along the
length of the coiled wire, e.g., an axis about which the wire
coils.
[0037] Outward surface 202 may connect with the first flat surface
204 along surface interface 203 and with the second flat surface
208 at surface interface 209. Inward surface 206 may connect with
the first flat surface 204 at surface interface 205 and with the
second flat surface 208 at surface interface 207. The surface
interfaces 203, 205, 207, 209 may be abrupt transitions defined by
a line extending along the wire 201 at the transition (as shown in
FIG. 2B) or the interfaces may be rounded transitions between
surfaces. In accordance with various embodiments, the inward
surface 206 and the outward surface 202 may be different sizes
relative to one another. For example, the inward surface 206 may be
wider than the outward surface 202. Alternatively, the inward
surface 206 may be narrower than the outward surface 202 (as shown
in FIG. 2B). In another example, the inward surface 206 may be the
same as the outward surface 202.
[0038] The surfaces 202, 204, 206, 208, may be oriented with
respect to the helical structure of the coil 200 in order to reduce
the interference contact between one coil and any adjacent coils
woven into a mesh carpet. In accordance with one embodiment, the
inward surface 206 may point toward a center axis 220 of the coil
200. Stated another way, inward surface 206 may be the portion of
the wire that is most proximate to the center axis 220 of the coil
200. Conversely, outward surface 202 may be the portion of the wire
that is most distal to the center axis 220 of the coil 200. In this
configuration, the outward surface forms the exterior of coil 200
and the inward surface 206 forms the interior surface of the coil
200.
[0039] In another embodiment, as illustrated in FIGS. 3A and 3B, a
coil 300 may have a flexibility improving major exterior surface.
The major exterior surface as shown in FIG. 3B is the perimeter of
the cross-section 301 of wire 300 which may include a plurality of
exterior surfaces. The plurality of exterior surfaces may include a
first concave surface 304 and a second concave surface 308. The
first concave surface 304 and the second concave surface 308 may
oppose one another. In various embodiments, the concave surfaces
304 and 308 may be positioned relative to one another at one of an
acute angle, an obtuse angle or parallel. The first concave surface
304 and the second concave surface 308 may be connected by an
outward surface 302 and an inward surface 306. Outward surface 302
may connect with the first concave surface 304 along surface
interface 303. Outward surface 302 may connect with the second
concave surface 308 at surface interface 309. Inward surface 306
may connect with the first concave surface 304 at surface interface
305. Inward surface 306 may connect with the second concave surface
308 at surface interface 307. The surface interfaces 303, 305, 307,
and 309 may be lines where the surfaces come to a point or the
surface interfaces 303, 305, 307, and 309 may be round transitions
between surfaces. (as shown in FIG. 3B) In accordance with various
embodiments, the inward surface 306 and the outward surface 302 may
be different sizes relative to one another. For example, the inward
surface 306 may be wider than the outward surface 302.
Alternatively, the inward surface 306 may be narrower than the
outward surface 302 (as shown in FIG. 3B). In another example, the
inward surface 306 may be the same as the outward surface 302.
[0040] Similar to the surfaces of coil 200, the surfaces 302, 304,
306, 308, of coil 300 may be oriented to the helical structure of
the coil 300 in order to reduce the interference contact between
one coil and any adjacent coils when woven into a mesh carpet. In
accordance with one embodiment, the inward surface 306 may point
toward a center axis 320 of the coil 300. Stated another way,
inward surface 306 may be the portion of the wire that is most
proximate to the center axis 320 of the coil 300. Conversely,
outward surface 302 may be the portion of the wire that is most
distal to the center axis 320 of the coil 300. In this
configuration, the outward surface forms the exterior of coil 300
and the inward surface 306 forms the interior surface of the coil
300.
[0041] In another embodiment, as illustrated in FIGS. 4A and 4B, a
coil 400 may have a flexibility improving major exterior surface.
The major exterior surface as shown in FIG. 4B is the perimeter of
the cross-section 401 of wire 400 which may include a plurality of
exterior surfaces. The plurality of exterior surfaces may include a
first flat surface 404 and a second flat surface 406. The first
flat surface 404 and the second flat surface 406 may oppose one
another. In various embodiments, the flat surfaces 404 and 406 may
be positioned relative to one another at one of an acute angle or
an obtuse angle. The first flat surface 404 and the second flat
surface 406 may be connected by a surface 402. Surface 402 may
connect with the first flat surface 404 along a first surface
interface 403. Surface 402 may connect with the second flat surface
406 at a second surface interface 407. First flat surface 404 and
second flat surface 406 may connect at a third surface interface
405. The surface interfaces 403, 405, and 407 may be lines where
the surfaces come to a point or the interfaces may be round
transitions between surfaces.
[0042] The surfaces 402, 404, or 406 may be oriented with respect
to the helical structure of the coil 400 in order to reduce the
interference contact between one coil and any adjacent coils when
woven into a mesh carpet. In accordance with one embodiment, the
surface interface 405 may point toward a center axis 420 of the
coil 400. Stated another way, the surface interface 405 may be the
portion of the wire that is most proximate to the center axis 420
of the coil 400. Conversely, outward surface 402 may be the portion
of the wire that is most distal to the center axis 420 of the coil
400. In this configuration, the outward surface forms the exterior
of coil 400 and the surface interface 405 forms the interior
surface of the coil 400. In another embodiment, the opposite may be
true. The surface interface 405 may be the portion of the wire that
is most distal to the center axis 420 of the coil 400, Surface 402
may be the portion of the wire that is most proximal to the center
axis 420 of the coil 400. In this configuration, the surface 402
forms the exterior of coil 400 and the surface interface 405 forms
the interior surface of the coil 400.
[0043] While each of the wires in the forgoing examples and
embodiments are illustrated and discussed as being symmetric, this
is not required. For example, one half of a wire cross-section may
include a flat surface as shown in the left half of FIG. 2B or FIG.
4B and one half of a wire cross-section may include a concave
surface as shown in right half of FIG. 3B. Any combination of
surfaces, symmetries, and wire cross-section designs may be
utilized to improve the flexibility of the mesh carpet. As such,
one of ordinary skill in the art may recognize that each of the
embodiments or examples discussed herein may be combined in order
to form a wire cross-section that achieves the flexibility goals of
the mesh carpet. While only limited examples are provided herein,
all forms of wire cross-sections that may be coiled and wire
cross-sections that improve the flexibility of the mesh carpet are
contemplated herein.
[0044] In order to form coils having a wire with a flexibility
improving cross-section, the wire with the cross-section may first
be formed. The wire cross-sections may be formed by, for example,
by drawing the wire through a die with the particular cross-section
embedded in the die. The output wire from the drawing die may then
include the flexibility improving cross-section. Alternatively, the
wire cross-sections may, be formed by, for example, rolling the
wire between two mandrels having the particular cross-section. The
output wire from the rolling process may then include the
flexibility improving cross-section. These particular wire
cross-sections may be formed prior to or during coiling of the wire
coils. For example, the drawn wire may be fed directly onto a
coiling mandrel. Alternatively, the coiling mandrel may include a
cross-section forming die such that as the wire is coiled onto the
mandrel, the wire can be forced (by either a rolling press or
similar device) into the mandrel die obtaining the particular wire
shape. It should be recognized that the flexibility improving
cross-section may be applied to the wires under any circumstances
or by any process known to one of ordinary skill in the art.
[0045] It should also be understood that the term wire does not
necessarily apply strictly to elongated metallic strands. As used
herein, the term wire may refer to any pliable strand or rod of
material made in any diameter or length suitable for winding into a
coil for use in forming a mesh carpet. The coils may be formed from
a variety of different materials. For example, ferromagnetic or
non-ferromagnetic (e.g. paramagnetic and diamagnetic) metals may be
utilized including iron, nickel cobalt, chromium, manganese,
ferromagnetic stainless steel (e.g., 400 series stainless steel),
copper, silver, gold, aluminum and non-ferromagnetic stainless
steel (e.g., 300 series stainless steel) or any other ferromagnetic
or non-ferromagnetic material as well, The various materials may be
utilized for corrosion resistance, magnetic characteristics,
conductive characteristics, aesthetics, weight, or workability. In
other embodiments, some of the coils may be non-metallic materials
including polymers, carbon fibers, or natural fibers capable of
being formed in and holding a coil shape. These non-metallic
materials may be utilized for insulating properties, weight, cost,
or other desirable properties. Therefore, in the context of this
application, the terms "coil" and "wire" may include forms made of
metallic or non-metallic materials.
[0046] Although a mesh carpet's flexibility may be improved by
pre-forming a particular wire cross-section, flexibility may also
be improved without requiring a particular wire cross-section.
Other flexibility improving procedures include processing the mesh
carpet after it has been formed. When originally formed, the mesh
carpet may have a natural circumference providing a default mesh
flexibility. This "mesh flexibility circumference" may be
understood as the unforced shape the mesh carpet makes when bent,
which may define a minimum bend radius for the carpet. By forcing a
formed mesh carpet into a smaller mesh flexibility circumference,
the mesh carpet flexibility may be improved. Traditionally the
process has been performed by a massaging machine as shown in FIG.
5. A massaging machine may have a plurality of cylinders (500, 501,
and 502) that gyrate up and down (e.g. along arrows a, b, and c
respectively) impacting the mesh carpet 100. The mesh carpet 100 is
moved between the cylinders.
[0047] As discussed above, this process may create aesthetically
unpleasing marks on the mesh carpet. Further, such marks may be
failure points or weak points for the mesh carpet. Typically the
marks are in the form of visual transverse lines across the strip
of mesh. In accordance with various embodiments, a system and
method for improving flexibility of a mesh carpet may also be
utilized without leaving behind impact marks. Such a system and
method for improving flexibility of a mesh carpet may be utilized
without impacting the mesh carpet.
[0048] In accordance with various embodiments and as shown in FIGS.
6-8, the flexibility of a mesh carpet may be improved by wrapping
the mesh carpet around a mandrel. Wrapping as used herein may
include more than minimal contact but instead may include the mesh
carpet traveling a significant distance around the circumference of
the mandrel, For example, wrapping the mesh carpet may include the
carpet traveling around at least 50 percent of the circumference of
the mandrel. Alternatively, wrapping the mesh carpet may include
the carpet traveling around 0-25 percent, 25-50 percent, 50-75
percent, or greater than 75 percent, of the circumference of the
mandrel. To improve the flexibility of the mesh carpet, the mandrel
may have a smaller radius than the natural circumference of the
mesh carpet. Forcing the mesh carpet around this smaller radius may
improve the flexibility of the mesh carpet. Contact between the
mandrel and the mesh carpet may also be maintained. Maintaining the
contact may prevent localized distortion in the mesh carpet from
contact with the mandrel. Instead, any distortion that occurs, to
improve the flexibility of the mesh carpet, may be continuous
across the length of the mesh carpet and not localized, In
accordance with the various embodiments as discussed herein,
various apparatuses may be utilized to improve the flexibility of
the mesh carpet.
[0049] In accordance with one embodiment, as shown in FIG. 6, a
mesh carpet 100 may be wrapped around mandrel 600. The mandrel 600
or the mesh carpet 100 may be movable. For example, as shown in
FIG. 6 mandrel 600 may be movable in more than one direction such
as along to arrow c. The mandrel 600 may be supported in a guide
604 that enables the travel of mandrel 600. In one embodiment, the
mandrel 600 may rotate according to arrow d in FIG. 6 around a
pivot 602. The rotation of the mandrel 600 may allow a static
contact between the mesh carpet 100 and the exterior surface of the
mandrel 600. The static contact may reduce abrasions or
deformations that may otherwise result from the mesh carpet 100
sliding across the mandrel 600. Alternatively, the mandrel 600 may
be stationary allowing carpet 600 to slide across the mandrel.
[0050] As indicated, the mesh carpet 100 may be movable.
Particularly one or more of an end 110 or 120 of the mesh carpet
100 may be movable. Moving the ends 110 or 120 in opposite
direction may cause the mesh carpet 100 to move back and forth
around mandrel 600. Similarly, as illustrated in FIG. 6, moving the
first end 110 and retaining the second end 120 may allow the mesh
carpet 100 to move back and forth around mandrel 600 with mandrel
600 be movable as well. A fixed position retaining device 620 may
be utilized to retain the second end 120 in place. It may be noted
that a restraint may be any device operable to hold an end of the
mesh carpet such that resistance may be applied to the movement of
the mesh carpet. For example, the restraint may be a clamp,
bracket, weight, or the force applied by a person holding the end
of the mesh carpet. The restraint may be fixed limiting movement of
the mesh carpet. For example, a clamping force indicated by arrows
e may be exerted against second end 120. As shown, a clamp may
retain that end in place. The first end 110 may have a movable
restraint 630. The movable restraint 630 may be operable to change
locations allowing the first end 110 of the mesh carpet 100 to move
relative to the second end 120. The movable restraint 630 may be
operative to receive a force from, for example, a cable 610 placing
the mesh carpet 100 in tension. In various embodiments, this may be
a constant tension. The tension may increase or decrease. For
example, in response to a sufficient force applied to the movable
restraint 630, the movable restraint 630 may cause the mesh carpet
100 to move. When the sufficient force is applied to movable
restraint 630, the mandrel may be operable to move in the direction
of the movable restraint 630. Once the mandrel 600 has made a full
travel toward second end 120, the mandrel may drive the carpet back
in the other direction, In this manner the apparatus is operable to
have the mandrel drive in one direction forcing the first end 110
of the carpet 100 toward the mandrel 600 while the mandrel 600
travels away from the second end 120 of the mesh carpet 100. This
motion causes the mesh carpet 100 to travel around the mandrel 600.
Then the movable restraint 630 may receive a force from cable 610
drawing the first end 110 of the mesh carpet 100 in the opposite
direction of the mandrel 600 and pulling the mandrel 600 in the
same direction. This enables the apparatus to work the mesh carpet
100 back and forth across mandrel 600.
[0051] In accordance with various embodiments, the mandrel 600 may
be smaller than the natural mesh flexibility circumference of mesh
carpet 100. Working the mesh carpet 100 back and forth around the
mandrel 600 may cause the mesh flexibility circumference of the
mesh carpet 100 to adapt to the circumference of the mandrel 600.
However, additional forces may aid in causing the mesh carpet 100
to adapt to the circumference of the mandrel 600. In accordance
with one embodiment, the mandrel 600 and the mesh carpet 100 may be
retained between a first plate 640 and a second plate 650. The mesh
carpet 100 may contact a first surface 642 on the first plate and a
second surface 652 on the second plate. The first plate 640 or the
second plate 650 may be movable toward or away from the other plate
as indicated by arrows a and b in FIG. 6. By moving the first plate
640 and the second plate 650 closer together, the contact between
the mesh carpet 100 and the surface of the plates (642 and 652) may
force the mesh carpet 100 into a smaller mesh flexibility
circumference. This motion between the plates may be continuously
driven as the mesh carpet 100 works back and forth around mandrel
600. Alternatively, this motion may be controlled such that after a
certain amount of time of the mesh carpet 100 working back and
forth around mandrel 600, the distance between the first plate 640
and the second plate 650 may decreases in an incremental amount.
This decrease may force the mesh flexibility circumference to adapt
to the circumference of the mandrel, thus allowing the plates to
move even closer and closer together. Once the mesh flexibility
circumference of the mesh carpet 100 substantially matches the
mandrel 600 circumference, a smaller mandrel can be placed in the
system and the process can continue. The plate force and working
the mesh carpet 100 around the mandrel circumference can be
continued until the desired mesh flexibility circumference is
achieved.
[0052] In accordance with various embodiments, the mandrel 600 or
the plates 640 and 650 may be configured to reduce any surface
abrasion or deformation on the mesh carpet 100 due to contact with
the mandrel 600 or the plates 640 and 650. For example, the mandrel
600 or the plates 640 and 650 may have a low friction surface.
Alternatively or in addition to, the mandrel 600 or the plates 640
and 650 may be made of a softer surface material than mesh carpet
100. Examples of low friction surfaces may include nylon,
polyoxymethylene, polished steal, a lubricated surface or any
similar low friction material or process for reducing the friction
of a surface. Similarly the nylon or polyoxymethylene or other
polymers may be a softer material than mesh carpet 100 limiting
their ability to scratch a harder surface. It should be appreciated
that a person of ordinary skill in the art may select other known
or developed materials accordingly.
[0053] In another embodiment, as illustrated in FIG. 7A-C, an
apparatus may include a plurality of mandrels 700, 710, and 720 for
improving the flexibility of a mesh carpet. Similar to other
embodiments as discussed herein, the mandrels 700, 710, or 720 may
be rotatable (along arrow c as shown in FIG. 7A-C) about pivots
701, 711, and 721 respectively or the mandrels 700, 710, or 720 may
be fixed. Mandrels 700, 710, or 720 may have mesh carpet 100
wrapped around the mandrels. Each end of the mesh carpet may be
movably restrained. The first end of the mesh carpet may be movable
along arrow a (as shown in FIG. 7A-C). The second end of the mesh
carpet may be movable along arrow b (as shown in FIG. 7A-C).
Placing a force on one end of the mesh carpet 100 and allowing the
other end of the mesh carpet 100 to move allows the mesh carpet to
move back and forth around the mandrel. As such, this apparatus may
allow the mesh flexibility circumference of mesh carpet 100 to
conform to the circumference of the mandrel. It may be noted that
after working the mesh carpet across a first mandrel, a second
smaller mandrel may be used to further increase the flexibility of
the mesh carpet. As such, mandrel 710 may be smaller in diameter
than mandrel 700 and mandrel 720 may be smaller in diameter than
mandrel 710.
[0054] In another embodiment, as illustrated in FIG. 8, an
apparatus may improving the flexibility of a mesh carpet by winding
the mesh carpet through a series of mandrels (e.g. mandrels 800,
810 and 820). The apparatus may include any number of mandrels such
as 1, 2, 3 . . . or N different mandrels. The mandrels (e.g. 800,
810 and 820) may be fixed or rotatable around pivots (e.g. 802,
812, and 822). If rotatable, the mandrels (e.g. 800, 810 and 820)
may be able to rotate clockwise or counter clockwise (e.g.
according to arrows c, d, and e).
[0055] In various embodiments, the mandrels may be offset from one
another. The offset may allow the mesh carpet 100 to be threaded
between and wrap around each of the different mandrels (e.g. 800,
810 and 820). In one example, the mandrels (e.g. 800, 810 and 820)
may be located relative to one another in a zigzag pattern as shown
in FIG. 8. The mesh carpet 100 may wrap around a first mandrel 800.
The mesh carpet may then wrap around a second mandrel 820 such that
both sides of the mesh carpet 100 are in contact with a mandrel.
The mesh carpet may wrap around a third mandrel 810. The mash
carpet may be retained on both ends. A first end may be restrained
by restraint 860. A second end may be restrained by restraint 870.
Restraints 860 or 870 may be movable restraints. In accordance with
one embodiment Restraints 860 or 870 may be operable to receive a
force causing the mesh carpet to move through the mandrels. The
force may alternate between restraint 860 and restraint 870. The
alternating force may cause mesh carpet to move back and forth as
illustrated by arrows a and b. Alternatively, the mesh carpet may
be moved continuously through the mandrel pattern in the same
direction.
[0056] As here may any number of mandrels in the pattern, the mesh
carpet 100 may move through an apparatus with a sufficiently long
path to allow the mesh carpet 100 to obtain the desired mesh
flexibility circumference. To aid in this, the mandrels may
decrease in size along the path of the mesh. For example, mandrel
820 may be smaller than mandrel 800.
[0057] This decrease in size may continue until the mandrel is the
size operable to form the desired mesh flexibility circumference.
With the mesh carpet continuing from one mandrel to another, the
apparatus path that the mesh carpet 100 follows may include various
guides e.g. 830, 840, and 850. The various guides (830, 840, and
850) may be operable to direct the mesh carpet 100 between
mandrels, keep mesh carpet 100 from falling off the mandrels, or
apply a force on mesh carpet 100 in order to conform the mesh
carpet to the circumference of the mandrel.
[0058] While FIGS. 6-8 are described herein as separate
embodiments, it may be noted that each of the embodiments may stand
alone or be combined with other embodiments. For example, the
apparatus described and exemplified in either FIG. 6 of FIG. 8 may
utilize multiple sizes of mandrels as exemplified in FIG. 7.
[0059] As indicated herein a method for improving the flexibility
of a mesh carpet may include using a wire with a specific surface,
In accordance with one embodiment, as shown in FIG. 9 an operation
900 for making a mesh carpet with improved flexibility may start.
In operation 910, a first coiled wire with a surface operable to
improve the flexibility of the mesh carpet may be obtained. The
wire may have a first surface and a second surface which oppose one
another. The first surface and the second surface may be operable
to contact the wire of other coils in a manner that improves
flexibility between the adjacent coils. In operation 920 a second
coiled wire may be obtained. In operation 930 the second wire may
be intertwined into the first wire to form a mesh carpet. In
operation 940 the first surface of the first coiled wire may
contact the second coiled wire. The process may continue with
intertwining additional coiled wires forming a mesh carpet.
Utilizing the shape of the wires with opposing surfaces as
discussed above with regard to FIGS. 2-4, the mesh carpet may be
formed with flexibility superior to a mesh carpet formed with
circular wires. In operation 950 the method may end.
[0060] In accordance with one embodiment, as shown in FIG. 10, an
operation 1000 for improving the flexibility of a mesh carpet may
start. In operation 1005, a first end of the mesh carpet may be
constrained. In operation 1010, a second end of the mesh carpet may
be constrained. In operation 1015, the mesh carpet may be located
between a first plate and a restraint plate. In operation 1020, the
mesh carpet may be wrapped around a first mandrel. In operation
1025, contact may be made between the mesh carpet and the first
mandrel. In operation 1030, the first mandrel may move away from a
fixed end of the mesh carpet. In operation 1035, the movable end of
the mesh carpet may be moved back to an original position. In
operation 1040, the mesh carpet may be contacted with the first
plate and the second plate. In operation 1045 the gap between the
first plate and the second plate may be decreased. In operation
1050, a smaller mesh flexibility circumference may be formed by
moving the mesh carpet around the first mandrel and between the
restraint plates. In operation 1055, the method may end once an
improved or desired flexibility is achieved in the mesh carpet
[0061] In accordance with one embodiment, as shown in FIG. 11, an
operation 1100 for improving the flexibility of a mesh carpet may
start. In operation 1110, the mesh carpet may be wrapped around a
first mandrel. In operation 1120, contact may be made between the
mesh carpet and the first mandrel. In operation 1130, the mesh
carpet may be moved back and forth across the mandrel. In operation
1140, the mesh carpet may be moved to a smaller mandrel.
Alternatively, the first mandrel may be replaced with a smaller
mandrel. In operation 1150, the mesh carpet may be moved back and
forth across the mandrel. This may continue to subsequent mandrels
such as a third or fourth mandrel. In operation 1160, the method
may end once an improved or desired flexibility is achieved in the
mesh carpet.
[0062] In accordance with one embodiment, as shown in FIG. 12, an
operation 1200 for improving the flexibility of a mesh carpet may
start. In operation 1210, the mesh carpet may be wrapped around a
first mandrel. In operation 1220, contact may be made or maintained
between the mesh carpet and the first mandrel. In operation 1230,
the mesh carpet may be wrapped around a second mandrel. The mesh
carpet may also be additionally wrapped around other mandrels such
as third mandrel and weaved between them in a zigzag path. In
operation 1240, the mesh carpet may be translated in a first
direction causing both sides of the mesh carpet to contact and bend
against each of the mandrels. In operation 1250, the mesh carpet
may be translated in a second direction. Alternatively the mesh
carpet may be continuously translated in the same direction and not
back and forth. In operation 1260, the method may end once an
improved or desired flexibility is achieved in the mesh carpet.
[0063] As used throughout this document in each of the embodiments,
aspects, examples, lists and various descriptions of the subject
matter contained herein, the word "or" is intended to be
interpreted in its inclusive form (e.g. and/or) not in its
exclusive form (e.g. only one of) unless explicitly modified to
indicate only one item in a list is intended (e.g. only one of A,
B, or C). For example, the phrase A, B, or C is intended to include
any combination of the elements. The phrase can mean only A. The
phrase can mean only B. The phrase can mean only C. The phrase can
mean A and B. The phrase can mean A and C. The phrase can mean B
and C. The phrase can mean A and B and C. This concept extends to
any length of list (e.g. 1, 2, 3 . . . n) used herein.
[0064] Although the foregoing discussion has presented specific
embodiments, the foregoing merely illustrates the principles of the
invention. Persons skilled in the art will recognize that changes
may be made in form and detail without departing from the spirit
and scope of the disclosure as various modifications and
alterations to the described embodiments will be apparent to those
skilled in the art, in view of the teachings herein. For example,
the processing steps may be performed in another order, or in
different combinations. It will thus he appreciated that those
having skill in the art will be able to devise numerous systems,
arrangements and methods which, although not explicitly shown or
described herein, embody the principles of the disclosure and are
thus within the spirit and scope of the present invention. From the
above description and drawings, it will be understood by those of
ordinary skill in the art that the particular embodiments shown and
described are for purposes of illustration only, and references to
details of particular embodiments are not intended to limit the
scope of the present invention, as defined by the appended
claims.
* * * * *