JP2019503865A - Integral expanded metal mesh with rolled linear strands - Google Patents

Abstract

A monolithic expanded metal mesh having a down-roll direction, wherein the mesh intersects a) a plurality of linear strands that are substantially parallel to the down-roll direction and b) a linear strand at a node A single expanded metal mesh comprising a plurality of intersecting strands. Also provided is a composite comprising an integral expanded metal mesh of the present disclosure and a polymer matrix. The monolithic expanded metal mesh and composite may be provided as a roll item with unbroken roll-like linear strands in some embodiments, without length limitations. An integrated expanded metal mesh method of the present disclosure is provided.
[Selection] Figure 1

Description

Detailed Description of the Invention

[Technical field]
The present disclosure has roll-like linear metal strands, thereby improving the tensile strength in the down-roll direction, and in some embodiments, unrestricted roll-like wires without length limitations. The present invention relates to an integral expanded metal mesh having a metal strand in a shape.
[Background technology]

  Currently, the expanded metal mesh is used to move the sheet from the roll of the metal sheet near the leading edge of the sheet using a tool that is arranged perpendicular to the metal sheet's down-roll direction, that is, parallel to the direction intersecting the sheet. Manufactured by repeating the process of cutting and bending simultaneously. The tool includes a number of triangular or arcuate protrusions that project in a direction orthogonal to the sheet. The sheet is supported on a support surface that includes a stationary cutting edge at its forward end that cuts the sheet in cooperation with the tool. When the tool comes down on the sheet near the front end of the sheet, a slit is cut into the sheet by each protrusion. In addition to slitting, each protrusion bends a thin metal strand adjacent to each slit downward, so that the strand protrudes in a direction perpendicular to the planar portion of the metal sheet. The tool leaves an uncut metal node between each strand. The sheet is fed forward and the process is repeated, but the tool moves alternately between the two positions with each stroke. The node at the first position is located in the middle between the slits at the second position, and vice versa. In some cases, the tool is stationary and the sheet moves alternately between the two positions with each stroke.

Referring to FIG. 3, expanded metal post-processing mesh 310 has the general shape of a parallelogram, that is, a rhombus (or potentially square), and is perpendicular to sheet down-roll direction 390. An air gap 320 having a main shaft 322 and a sub shaft 324 parallel to the sheet down-roll direction 390 is included. The void is bounded by diagonal metal strands 330 that are oriented diagonally relative to the sheet's down-roll direction 390. Diagonal metal strands 330 meet at node 340.
[Summary of Invention]

  Briefly, the present disclosure is a unitary expanded metal mesh having a down roll direction, wherein the mesh is a) a plurality of linear strands that are substantially parallel to the down roll direction, and b). The integrated expanded metal mesh includes a plurality of intersecting strands intersecting with the linear strand at the node, and the integrated expanded metal mesh is a length of more than 3.00 m measured in the down roll direction. provide. In some embodiments, the linear strands are parallel to the down-roll direction with an angular tolerance of +/− 10 ° throughout the length of the mesh. In some embodiments, the linear strands are parallel to the down-roll direction with a net angle tolerance of +/− 10 ° accumulated over the length of the mesh. In some embodiments, the integral expanded metal mesh has a length measured in the down roll direction of greater than 8.00 meters, and in some embodiments, the length measured in the down roll direction is 900. Over 00m. In some embodiments, the integral expanded metal mesh comprises copper, tin, gold, silver, nickel, zinc, iron, aluminum, or alloys thereof. In some embodiments, the integral expanded metal mesh has a thickness of less than 1.800 mm and a thickness greater than 0.010 mm. In some embodiments, the integral expanded metal mesh has an average distance between nodes of less than 4.000 cm and greater than 0.030 cm as measured along the linear strands. In some embodiments, the unitary expanded metal mesh is a unitary stretched and unfolded metal mesh. Additional embodiments of the integral expanded metal mesh of the present disclosure are described below in “Selective Embodiments”.

  In another aspect, the present disclosure provides a composite material comprising c) an integral expanded metal mesh as described in the present disclosure and d) a polymer matrix. In various embodiments, the polymer matrix may be an uncured curable resin, a partially cured curable resin, a cured curable resin, a thermosetting resin, or an epoxy resin. In some embodiments, the composite material may further include one or both of e) a woven fiber scrim or f) a non-woven fiber scrim. In some embodiments, the composite material may be a sheet material having a thickness of less than 6.00 mm and greater than 0.020 mm. Additional embodiments of the composite materials of the present disclosure are described below in “Selective Embodiments”.

  In another aspect, the present disclosure is a method for producing an integral expanded metal mesh as described in the present disclosure, wherein g) a step of preparing a metal sheet having a down roll direction, and h) the vicinity of the tip of the metal sheet. The cutting step and the bending step of the metal strand of the sheet are simultaneously performed using a tool arranged obliquely with respect to the down-roll direction of the metal sheet, and the cutting step is separated with an interval in the sheet. Cutting a row of slits, wherein the bending step bends the thin metal strands of the sheet adjacent to each slit downward so that the strands project in a direction perpendicular to the plane portion of the metal sheet. , Step, i) step of feeding the metal sheet forward in the down-roll direction, and j) step h) by repeating step h), the interval adjacent to the row of slits is A step of such a line substantially parallel to the down roll direction of the metal sheet, to provide a manufacturing method comprising. In some embodiments, the tool includes a plurality of protrusions extending in a direction orthogonal to the sheet. In some embodiments, the protrusion has a triangular or arcuate shape extending in a direction orthogonal to the sheet. In some embodiments, the slit rows are parallel slit rows. In some embodiments, the rows of slits are collinear rows of slits. In some embodiments, the tool alternates between two positions relative to the lateral direction of the sheet with each repetition of step h). In other embodiments, the tool does not move position relative to the lateral direction of the sheet during the repetition of step h). In some embodiments, the step of providing a metal sheet includes the step of providing a roll of metal sheet, wherein the roll of metal sheet has a down roll direction parallel to the longitudinal direction of the rolled metal sheet. A roll of metal sheet, in which case the process is typically a continuous process by roll. Further embodiments of the disclosed method are described in “Selective Embodiments” below.

  In another aspect, the present disclosure is a method for producing an integrated expanded metal mesh according to the present disclosure, wherein p) a step of preparing a metal sheet having a down roll direction, and q) a step of forming a slit in the sheet. Thereby forming a slit metal sheet having a plurality of spaced apart slit rows, the slit rows being oriented obliquely relative to the sheet's down roll direction and adjacent to the slit rows A step of forming a slit in the sheet so that the interval to be a line substantially parallel to the down-roll direction of the metal sheet, and r) the slit metal sheet with respect to the down-roll direction of the metal sheet A process of stretching a slit metal sheet, which is a process of stretching in a non-parallel direction, thereby forming an integral expanded metal mesh. If, to provide a manufacturing method comprising. In some embodiments, the slit rows are parallel slit rows. In some embodiments, the rows of slits are collinear rows of slits. In some embodiments, the step of providing a metal sheet includes the step of providing a roll of metal sheet, wherein the roll of metal sheet has a down roll direction parallel to the longitudinal direction of the rolled metal sheet. A roll of metal sheet, in which case the process is typically a continuous process by roll. Further embodiments of the disclosed method are described in “Selected Embodiments” below.

  In another aspect, the present disclosure is a unitary metal mesh having a down-roll direction, the mesh a) a plurality of linear strands that are substantially parallel to the down-roll direction, and b) a line at the node. A unitary metal mesh having a length measured in the down roll direction of greater than 3.00 m, and in some embodiments, the length measured in the down roll direction. Provide an integral metal mesh with a length greater than 900.00 m. Additional embodiments of the integral metal mesh of the present disclosure are described below in “Selective Embodiments”.

  What has not been described in the prior art and is provided by the present disclosure is an integral metal mesh having a roll of linear metal strands, and in some embodiments, without length limitations It is an unbroken roll-shaped linear metal strand, and is thus an integral metal mesh with improved tensile strength in the down-roll direction. Thus, in some embodiments, the monolithic metal mesh provided by the present disclosure is a continuous, long roll, such as automated fiber placement or automated tape lay up. Excellent for use in automated applications that use any material.

  All scientific and technical terms used herein have meanings commonly used in the art unless otherwise specified.

  As used herein and in the appended claims, the term “unitary” excludes objects formed by combining two or more articles. For example, like a screen door, a knitted metal mesh is formed by combining a plurality of sets of wires, so it is not integral, and any mesh derived therefrom is not integral.

  As used herein and in the appended claims, the term “expanded mesh” is formed by drilling holes in the sheet or otherwise removing material and cutting the sheet to form holes. Exclude the mesh that will be used. In some embodiments, an “expanded mesh” of the present disclosure is a mesh or part of a mesh formed by cutting and stretching a sheet or a portion of a sheet to increase its area and form a mesh. Meaning, limited to “stretched and unfolded mesh”.

  As used herein and in the appended claims, the term “continuous process by roll” refers to the loading of the raw material of the rolled article until at least one of the raw materials of the rolled article is used up. A process that runs continuously.

  As used herein and in the appended claims, the singular forms “a”, “an”, and “the” include embodiments having a plurality of referents unless the content clearly dictates otherwise. .

  As used herein and in the appended claims, the term “or” is generally employed in its sense including “and / or” unless the content clearly dictates otherwise.

  As used herein, “have”, “having”, “include”, “including”, “comprise”, “comprising”, etc. Are used in their open-ended sense and generally mean “including but not limited to”. It will be understood that the terms “consisting of” and “consisting essentially of” are encompassed by terms such as “including”.

9 is an expanded metal mesh as described in some embodiments of the present disclosure, wherein 190 indicates the down roll direction of the sheet. A slit metal foil useful in some embodiments of Method II of the present disclosure, wherein 290 indicates the down roll direction of the sheet. It is an expanded metal mesh of a prior art, 390 shows the down roll direction of a sheet | seat. [Detailed description]

  The present disclosure provides an integral expanded metal mesh having a roll of linear metal strands. As a result, the tensile strength in the mesh down-roll direction is improved. In some embodiments, the unitary expanded metal mesh includes unbroken, rolled, linear metal strands with no length limitations. In many embodiments, the integral expanded metal mesh is provided as a roll item or incorporated into a roll item, and in many such embodiments, an uninterrupted roll within the mesh. The length of the linear metal strand is limited only by the length of the roll. As a result, the integral expanded metal mesh of the present disclosure is particularly useful for applications that use long and continuous roll materials, such as automatic fiber placement and automatic tape application, and is supplied as a roll of 1000 m or longer. Can be done.

  Referring to FIG. 1, one embodiment of an integral expanded metal mesh 110 of the present disclosure has the general shape of a parallelogram, that is, a rhombus (or potentially a square), and the sheet 190 has a down roll direction. With respect to the main shaft 122 in a direction that is not parallel or perpendicular to the down-roll direction of the sheet 190 and to the down-roll direction of the sheet 190 A void 120 having a minor axis 124 in a direction that is neither parallel nor perpendicular. The voids are separated by linear strands 135 and intersecting strands 130 that are oriented generally parallel to the down roll direction of the sheet 190, and the intersected strands 130 are oriented relative to the down roll direction of the sheet 190. Are oriented diagonally or vertically. The linear strand 135 and the intersecting strand 130 intersect at a node 140. In some embodiments, the linear strand 135 is an uninterrupted, roll-shaped strand with no length limitation, that is, the length is limited only by the roll length of the mesh.

  The linear strand is substantially parallel to the down roll direction. In the present disclosure, “parallel to the down-roll direction” means orientation of a sheet or mesh in a general plane (“right or left”), and displacement outside the plane (“up or down”). ) Is ignored. In some embodiments, the linear strands are parallel to the down-roll direction with an angular tolerance of +/− 10 ° throughout the length of the mesh, and in some embodiments, the tolerance is less. In some embodiments, the net deviation from the parallel state of the linear strands is small over long distances so that each linear strand fits within the mesh for a very long length. In some embodiments, the net deviation of the linear strands from the parallel state results in a cumulative or positive or negative value, and each linear strand spans the entire length of a given mesh. Start at one end of the mesh and reach the other end of the mesh. The overall length of a given mesh is typically at least 3.00 m, more typically at least 4.00 m, more typically at least 6.00 m, and more typically at least 8 0.000 m, more typically at least 12.00 m. Thus, in some embodiments, the linear strands are parallel to the down-roll direction with a net angle tolerance of up to +/− 10 ° (deviation from parallel accumulated over the length of the mesh). Yes, in some embodiments, there is less tolerance.

  In some embodiments, the integral expanded metal mesh of the present disclosure is provided as a rolled item having a length greater than 3.00 m, and in some embodiments, greater than 4.00 m, In some embodiments, greater than 6.00 m, in some embodiments, greater than 8.00 m, in some embodiments, greater than 12.00 m, and in some embodiments, 22. Greater than 00m, in some embodiments greater than 52.00m, in some embodiments greater than 520.00m, in some embodiments greater than 900.00m, In embodiments, it is greater than 1400.00 m. In some embodiments, the expanded metal mesh is unitary without any joints or splices or seams throughout the length of the roll.

  In some embodiments, the integral expanded metal mesh of the present disclosure is incorporated into a composite material, which in some embodiments is a sheet material. In some embodiments, the composite material comprises a unitary expanded metal mesh of the present disclosure and a polymer matrix. Suitable polymer matrices include thermoplastic resins, uncured curable resins, partially cured or B-stage curable resins, cured curable resins, thermosetting resins, and in some embodiments May contain an epoxy resin. As an additional component of the composite material, a woven fiber scrim, a non-woven fiber scrim, filled particles, a pigment and the like may be included.

  The inventors of the present invention have developed a tape in which an epoxy resin matrix and an integral expanded metal mesh of the present disclosure are combined, as shown in FIG. 3, in which the same epoxy resin matrix and a conventional expanded metal mesh are combined. It has been found that it can withstand a peak load 2.5 times as large as

  The integral expanded metal mesh of the present disclosure may be manufactured by any suitable method, including methods I, Ib, II described herein.

Manufacturing method I
In one embodiment, the integral expanded metal mesh of the present disclosure repeats the process of simultaneously cutting and bending the sheet near the tip using a tool positioned diagonally with respect to the down-roll direction of the metal sheet. Thus, it is manufactured from a roll of metal sheet. The tool includes a number of protrusions, typically triangular or arcuate, extending in a direction orthogonal to the sheet. The protrusions are typically parallel to each other and more typically collinear. The sheet is supported on a support surface that includes a stationary cutting edge at its forward end that cuts the sheet in cooperation with the tool. Therefore, the cutting end is also arranged obliquely with respect to the down-roll direction of the metal sheet and parallel to the tool. When the tool comes down on the sheet near the front end of the sheet, a slit is cut into the sheet by each protrusion. In addition to slit slitting, each protrusion bends a thin metal strand adjacent to each slit downward, thereby causing the strand to protrude in a direction perpendicular to the planar portion of the metal sheet.

  The tool leaves uncut metal nodes between each strand. The sheet is fed forward and the process is repeated. Adjacent rows of nodes should be lines that are substantially parallel to the down-roll direction of the metal sheet.

  In some embodiments, the tool alternates between two positions with each stroke. The node at the first position is located in the middle between the slits at the second position, and vice versa. In some cases, the tool is stationary and the sheet moves alternately between two positions for each stroke. In either case, with each stroke, the tool moves alternately between the two positions in the direction transverse to the sheet (ie, the direction across the sheet).

Manufacturing method Ib
In some embodiments of Method I (designated Method Ib), neither the tool nor the sheet move between positions alternately. Instead, they remain in one relative position with respect to each other, except for the movement of the sheets in the down-roll direction. The tool does not move in the lateral direction with respect to the sheet (that is, the direction across the sheet) between strokes. The position is chosen so that the adjacent row nodes become lines that are substantially parallel to the down-roll direction of the metal sheet with repeated strokes. In such an embodiment, the manufacturing mechanism is simplified and capital expenditures can be reduced. Also, the speed of the line is increased by eliminating the need to move the tool (or sheet) between alternate positions.

Manufacturing method II
In one embodiment, and with reference to FIG. 2, an integral expanded metal mesh of the present disclosure begins with a row of slits 250 oriented obliquely from a roll of metal sheet 210 with respect to sheet down-roll direction 290. It is manufactured by creating. The slits 250 in each row are typically parallel to each other and more typically collinear. Within each row of slits, the integral expanded metal mesh node 240 is the spacing between the slits. Nodes 240 adjacent to the row of slits are lines that are substantially parallel to the down-roll direction of the metal sheet. The slit formation may be performed by any suitable method without including limitations such as rotary cutting and laser cutting.

  In the second step of Method II, the slit sheet is in a direction perpendicular to the sheet's down-roll direction 290 or oblique to the sheet's down-roll direction 290 but not parallel to the slit 250, And the slit opens to form a void having the general shape of a parallelogram, increasing the width of the sheet. The stretching step may be performed by any suitable method.

Manufacturing method III
In one embodiment, an integral metal mesh (ie, an unexpanded metal mesh), similar in some respects to the integral expanded metal mesh described in this disclosure, is perforated and rotated into a metal sheet. It may be manufactured by cutting, die cutting, or laser cutting and providing many holes. In some embodiments, these holes are generally in the shape of a parallelogram as described above. This method does not increase the area of the metal sheet and produces metal scrap in the form of many very small pieces. Metal scrap accounts for the bulk of the original weight of the metal sheet and is often heavier than half the original weight. This method has practical limitations in that it is difficult to cover a large area, the density is reduced, and the strand thickness is thin.

Additional Process Steps In some embodiments, the integrated expanded metal mesh manufacturing method of the present disclosure may further include steps of planar processing, plating, and slit formation. These additional steps may be performed in any number and in any suitable order. Planar processing may be performed in any suitable manner, including but not limited to pressing, calendaring, and hammering, with heating or without heating. The plating process may be performed by any suitable method including, but not limited to, electroplating, non-electroplating, chemical plating and the like. Slit formation may be performed by any suitable method, including but not limited to the use of cutting tools, blades, lasers, and the like.

Alternative Embodiments The following embodiments, indicated by letters and numbers, are intended to further illustrate the present disclosure and should not be construed to unduly limit the present disclosure.

M1 is an integral expanded metal mesh having a down-roll direction,
a) a plurality of linear strands substantially parallel to the down roll direction;
b) comprising a plurality of intersecting strands that intersect the linear strands at the nodes;
The integral expanded metal mesh is an integral expanded metal mesh whose length measured in the down roll direction is more than 3.00 m.

  M2 Integral expanded metal mesh as described in embodiment M1, wherein the linear strands are parallel to the down roll direction with an angular tolerance of +/− 10 ° over the entire length of the mesh. Metal mesh.

  The integral expanded metal mesh of embodiment M2, wherein the angular tolerance across the length of the M3 mesh is +/− 8 °.

  The integral expanded metal mesh of embodiment M2, wherein the angular tolerance across the length of the M4 mesh is +/− 6 °.

  The integral expanded metal mesh of embodiment M2, wherein the angular tolerance across the length of the M5 mesh is +/− 5 °.

  The integral expanded metal mesh of embodiment M2, wherein the angular tolerance across the length of the M6 mesh is +/- 4 [deg.].

  The integrated expanded metal mesh of embodiment M2, wherein the angular tolerance across the length of the M7 mesh is +/- 3 [deg.].

  The integrated expanded metal mesh of embodiment M2, wherein the angular tolerance across the length of the M8 mesh is +/- 2 °.

  The integral strand according to any of embodiments M1-M8, wherein the M9 linear strands are accumulated over the length of the mesh and the net angle tolerance is +/− 10 ° and parallel to the down roll direction. Expanded metal mesh.

  The integrated expanded metal mesh of embodiment M9, wherein the net angle tolerance is +/− 8 ° accumulated over the length of the M10 mesh.

  The integrated expanded metal mesh of embodiment M9, wherein the net angle tolerance is +/− 6 ° accumulated over the length of the M11 mesh.

  The integrated expanded metal mesh of embodiment M9, wherein the net angle tolerance is +/− 5 ° accumulated over the length of the M12 mesh.

  The integrated expanded metal mesh of embodiment M9, wherein the net angle tolerance is +/− 4 ° accumulated over the length of the M13 mesh.

  The integrated expanded metal mesh according to embodiment M9, wherein the net angle tolerance is +/− 3 ° accumulated over the length of the M14 mesh.

  The integrated expanded metal mesh according to embodiment M9, wherein the net angle tolerance is +/− 2 ° accumulated over the length of the M15 mesh.

  The integrated expanded metal mesh according to any of the previous embodiments, wherein the length measured in the down roll direction is greater than 4.00 m.

  The integrated expanded metal mesh according to any of the previous embodiments, wherein the length measured in the down roll direction is greater than 6.00 m.

  The integrated expanded metal mesh according to any of the previous embodiments, wherein the length measured in the down-roll direction is greater than 8.00 m.

  The integrated expanded metal mesh according to any of the preceding embodiments, wherein the length measured in the down roll direction is greater than 12.00 m.

  The integrated expanded metal mesh according to any of the previous embodiments, wherein the M20 integrated expanded metal mesh has a length measured in the down roll direction of greater than 52.00 m.

  The integrated expanded metal mesh according to any of the preceding embodiments, wherein the M21 integrated expanded metal mesh has a length measured in the down roll direction of greater than 520.00 m.

  The M22 integral expanded metal mesh according to any of the preceding embodiments, wherein the length measured in the down roll direction is greater than 900.00 m.

  The integrated expanded metal mesh according to any of the previous embodiments, wherein the M23 integral expanded metal mesh has a length measured in the down roll direction of greater than 1400.00 m.

  The integrated expanded metal mesh according to any of the previous embodiments, which is a roll having a length greater than M24 520.00 m.

  The integrated expanded metal mesh according to any of the previous embodiments, which is a roll having a length of M25 greater than 900.00 m.

  M26 The integral expanded metal mesh according to any of the previous embodiments, which is a roll having a length greater than 1400.00 m.

  The integrated expanded metal mesh of any of the preceding embodiments, wherein the M27 integral expanded metal mesh has a width length measured in a direction perpendicular to the down roll direction of greater than 1.00 m.

  The integrated expanded metal mesh according to any of the previous embodiments, wherein the length of the width measured in the direction perpendicular to the down roll direction is greater than 2.00 m.

  M29. An integral expanded metal mesh according to any of the previous embodiments, wherein the linear strands and intersecting strands form a repeating pattern of voids.

  The integral expanded metal mesh of any of the preceding embodiments, wherein the M30 linear strands and the intersecting strands form a repeating pattern of voids in the form of substantially parallelograms.

  The integrated expanded metal mesh according to embodiment M30, wherein the parallelogram has a major axis that is neither parallel nor perpendicular to the downroll direction and a minor axis that is neither parallel nor perpendicular to the downroll direction.

  The integral expanded metal mesh according to any of the previous embodiments comprising M32 copper.

  The integrated expanded metal mesh according to any of the previous embodiments comprising M33 tin.

  The integrated expanded metal mesh according to any of the previous embodiments, comprising M34 bronze.

  The integral expanded metal mesh according to any of the previous embodiments comprising M35 gold.

  The integral expanded metal mesh according to any of the previous embodiments comprising M36 silver.

  The integral expanded metal mesh according to any of the previous embodiments comprising M37 nickel.

  The integral expanded metal mesh according to any of the previous embodiments comprising M38 zinc.

  The integrated expanded metal mesh according to any of the previous embodiments comprising M39 iron.

  An integral expanded metal mesh according to any of the previous embodiments comprising M40 aluminum.

  The integrated expanded metal mesh of any of the previous embodiments, plated with M41 nickel.

  The integrated expanded metal mesh of any of the previous embodiments, plated with M42 zinc.

  The integrated expanded metal mesh of any of the preceding embodiments, plated with M43 tin.

  M44 The integral expanded metal mesh of any of the previous embodiments, having a thickness of less than 1.800 mm.

  M45. An integral expanded metal mesh according to any of the previous embodiments having a thickness of less than 0.800 mm.

  M46. An integral expanded metal mesh according to any of the previous embodiments, having a thickness of less than 0.400 mm.

  The integrated expanded metal mesh according to any of the previous embodiments, wherein M47 has a thickness of less than 0.200 mm.

  The integrated expanded metal mesh according to any of the previous embodiments, wherein M48 has a thickness of less than 0.040 mm.

  M49. An integral expanded metal mesh according to any of the previous embodiments, having a thickness of less than 0.020 mm.

  The integrated expanded metal mesh according to any of the previous embodiments, having a thickness of M50 greater than 0.010 mm.

  M51 The integral expanded metal mesh according to any of embodiments M1-M49, having a thickness greater than 0.030 mm.

  M52 The integral expanded metal mesh of any of the previous embodiments, wherein the average distance between nodes, measured along the linear strand, is less than 4.000 cm.

  M53 The integral expanded metal mesh of any of the previous embodiments, wherein the average distance between nodes, measured along the linear strand, is less than 0.900 cm.

  M54 The integral expanded metal mesh of any of the preceding embodiments, wherein the average distance between nodes, measured along the linear strand, is less than 0.450 cm.

  M55 The integral expanded metal mesh of any of the previous embodiments, wherein the average distance between nodes, measured along the linear strand, is less than 0.200 cm.

  M56 The integral expanded metal mesh of any of the previous embodiments, wherein the average distance between nodes, measured along the linear strand, is greater than 0.030 cm.

  M57. The integral expanded metal mesh according to any of the previous embodiments, wherein the integral expanded metal mesh is an integral stretched expanded metal mesh.

C1 composite material,
c) an integrated expanded metal mesh according to any of embodiments M1 to M37;
d) a composite material comprising a polymer matrix.

  C2 The composite material of embodiment C1, wherein the polymer matrix is an uncured curable resin.

  C3. The composite material of embodiment C1, wherein the polymer matrix is a partially cured curable resin.

  C4 The composite material of embodiment C1, wherein the polymer matrix is a cured curable resin.

  The composite material according to any of embodiments C1-C4, wherein the C5 polymer matrix is a thermosetting resin.

  C6 The composite material according to any of embodiments C1-C5, wherein the polymer matrix is an epoxy resin.

  C7 The composite material of embodiment C1, wherein the polymer matrix is a thermoplastic resin.

C8
e) The composite material according to any of embodiments C1-C7, further comprising a woven fiber scrim.

  C9 The composite material of embodiment C8, wherein the woven fiber scrim comprises glass fibers.

  The composite material according to any of embodiments C8-C9, wherein the C10 woven fiber scrim comprises ceramic fibers.

  C11 The composite material according to any of embodiments C5-C10, wherein the woven fiber scrim comprises carbon fibers.

  C12 The composite material according to any of embodiments C5-C11, wherein the woven fiber scrim comprises polymer fibers.

C13
f) The composite material according to any of embodiments C1-C12, further comprising a nonwoven fiber scrim.

  C14 The composite material of embodiment C13, wherein the nonwoven fiber scrim comprises glass fibers.

  C15 The composite material according to any of embodiments C13 to C14, wherein the nonwoven fiber scrim comprises ceramic fibers.

  The composite material according to any of embodiments C13-C15, wherein the C16 nonwoven fiber scrim comprises carbon fibers.

  C17 The composite material according to any of embodiments C13 to C16, wherein the nonwoven fiber scrim comprises polymer fibers.

  C18 The composite material according to any one of embodiments C1 to C17, which is a sheet material having a thickness of less than 6.00 mm.

  C19 The composite material according to any one of embodiments C1 to C17, which is a sheet material having a thickness of less than 3.00 mm.

  C20 The composite material according to any one of embodiments C1 to C17, which is a sheet material having a thickness of less than 0.600 mm.

  C21 The composite material according to any one of embodiments C1 to C17, which is a sheet material having a thickness of less than 0.300 mm.

  C22 The composite material according to any of embodiments C1 to C21, which is a sheet material having a thickness of greater than 0.020 mm.

  C23 The composite material according to any one of embodiments C1 to C18, which is a sheet material having a thickness of less than 0.040 mm.

PA1
g) preparing a metal sheet having a down roll direction;
h) A step of simultaneously performing a cutting step in the vicinity of the front end portion of the metal sheet and a bending step of the metal strand of the sheet by using a tool disposed obliquely with respect to the down-roll direction of the metal sheet. Cutting a row of spaced apart slits in the sheet, wherein the bending process bends the thin metal strands of the sheet adjacent to each slit downward so that the strands are in the flat portion of the metal sheet. A process of projecting in a direction perpendicular to the direction,
i) sending the metal sheet forward in the down-roll direction;
j) repeating step h), such that the spacing adjacent to the row of slits is a line substantially parallel to the down-roll direction of the metal sheet. The manufacturing method of the integral expanded metal mesh in any one of -M57.

  The method of embodiment PA1, wherein the PA2 tool includes a plurality of protrusions extending in a direction orthogonal to the sheet.

  PA3 The method of embodiment PA2, wherein the protrusion has a triangular shape or an arc shape extending in a direction orthogonal to the sheet.

  PA4. A method according to any of embodiments PA1-PA3, wherein with each repetition of step h), the tool moves alternately between two positions relative to the lateral direction of the sheet.

  PA5. Method according to any of embodiments PA1-PA3, wherein the tool does not move position relative to the lateral direction of the sheet during each iteration of step h).

  PA6 The method according to any of embodiments PA1-PA5, wherein the rows of slits are parallel rows of slits.

  The method according to any of embodiments PA1-PA5, wherein the rows of PA7 slits are rows of slits on the same line.

  PA8 Any of Embodiments PA1 to PA7, wherein the step of preparing a metal sheet having a down-roll direction includes the step of preparing a roll of a metal sheet having a down-roll direction parallel to the longitudinal direction of the roll-shaped metal sheet The method of crab.

  The method of embodiment PA8, which is a continuous process with a PA9 roll.

  The method of any of embodiments PA8-PA9, wherein the roll of PA10 metal sheet has a length greater than 120.00 m.

  The method of any of embodiments PA8-PA9, wherein the roll of PA11 metal sheet has a length greater than 520.00 m.

PB1 A method for producing an integrated expanded metal mesh according to any one of Embodiments M1 to M57,
p) preparing a metal sheet having a down-roll direction;
q) forming a slit in the sheet to form a metal slit sheet having a plurality of spaced apart slit rows, wherein the slit rows are oblique with respect to the sheet down-roll direction. Directed so that the spacing between adjacent rows of slits is a line substantially parallel to the down-roll direction of the metal sheet.

PB2
r) The method of embodiment PB1, further comprising the step of stretching the metal slit sheet in a direction that is not parallel to the down-roll direction of the metal sheet to form an integral expanded metal mesh.

  The method of any of embodiments PB1-PB2, wherein the rows of PB3 slits are rows of parallel slits.

  The method according to any of embodiments PB1-PB2, wherein the rows of PB4 slits are rows of slits on the same line.

  Any of Embodiments PB1 to PB4, wherein the step of preparing a metal sheet having a PB5 down roll direction includes the step of preparing a roll of a metal sheet having a down roll direction parallel to the long side of the roll-shaped metal sheet. The method of crab.

  The method of embodiment PB5, which is a continuous process with PB6 rolls.

  The method of any of embodiments PB5 to PB6, wherein the roll of PB7 metal sheet has a length greater than 120.00 m.

  The method of any of embodiments PB5 to PB6, wherein the roll of PB8 metal sheet has a length greater than 520.00 m.

PPM1 is an integral metal mesh having a down roll direction,
a) a plurality of linear strands substantially parallel to the down roll direction;
b) comprising a plurality of intersecting strands that intersect the linear strands at the nodes;
The integral metal mesh is an integral metal mesh whose length measured in the down roll direction is more than 3.00 m.

  PM2 The unitary metal mesh of embodiment PM1, wherein the linear strands are parallel to the down roll direction with an angular tolerance of +/− 10 ° over the entire length of the mesh.

  The solid metal mesh of embodiment PM2, wherein the angular tolerance across the length of the PM3 mesh is +/− 8 °.

  The integral metal mesh of embodiment PM2, wherein the angular tolerance across the length of the PM4 mesh is +/− 6 °.

  The solid metal mesh of embodiment PM2, wherein the angular tolerance across the length of the PM5 mesh is +/− 5 °.

  The solid metal mesh of embodiment PM2, wherein the angular tolerance across the length of the PM6 mesh is +/− 4 °.

  The solid metal mesh of embodiment PM2, wherein the angular tolerance across the length of the PM7 mesh is +/− 3 °.

  The solid metal mesh of embodiment PM2, wherein the angular tolerance across the length of the PM8 mesh is +/− 2 °.

  PM9 The integral strand according to any of embodiments PM1-PM8, wherein the linear strands are parallel to the down roll direction with a net angle tolerance of +/− 10 ° accumulated over the length of the mesh. Metal mesh.

  The solid metal mesh of embodiment PM9, wherein the net angle tolerance is +/− 8 ° accumulated over the entire length of the PM10 mesh.

  The solid metal mesh of embodiment PM9, wherein the net angle tolerance is +/− 6 ° accumulated over the entire length of the PM11 mesh.

  The integrated metal mesh according to embodiment PM9, wherein the net angle tolerance is +/− 5 ° accumulated over the entire length of the PM12 mesh.

  The integrated metal mesh of embodiment PM9, wherein the net angle tolerance is +/− 4 ° accumulated over the entire length of the PM13 mesh.

  The integral metal mesh of embodiment PM9, wherein the net angle tolerance is +/− 3 ° accumulated over the entire length of the PM14 mesh.

  The solid metal mesh of embodiment PM9, wherein the net angle tolerance is +/− 2 ° accumulated over the entire length of the PM15 mesh.

  PM16 The integral metal mesh according to any of the preceding embodiments, wherein the integral metal mesh has a length measured in the down roll direction of greater than 4.00 m.

  PM17 The integral metal mesh according to any of the preceding embodiments, wherein the integral metal mesh has a length measured in the down roll direction of greater than 6.00 m.

  PM18 The integral metal mesh according to any of the preceding embodiments, wherein the integral metal mesh has a length measured in the down roll direction of greater than 8.00 m.

  PM19 The integral metal mesh according to any of the preceding embodiments, wherein the integral metal mesh has a length measured in the down roll direction of greater than 12.00 m.

  PM20 The integral metal mesh according to any of the preceding embodiments, wherein the length of the integral metal mesh measured in the down roll direction is greater than 52.00 m.

  PM21 The integral metal mesh according to any of the preceding embodiments, wherein the integral metal mesh has a length measured in the down roll direction of greater than 520.00 m.

  PM22 The integral metal mesh according to any of the preceding embodiments, wherein the integral metal mesh has a length measured in the down roll direction of greater than 900.00 m.

  PM23 The integral metal mesh according to any of the preceding embodiments, wherein the integral metal mesh has a length measured in the down roll direction of greater than 1400.00 m.

  PM24 An integral metal mesh according to any of the previous embodiments, which is a roll having a length greater than 520.00 m.

  PM25 An integral metal mesh according to any of the previous embodiments, which is a roll having a length greater than 900.00 m.

  PM26 Integral metal mesh according to any of the previous embodiments, which is a roll having a length greater than 1400.00 m.

  PM27 The integral metal mesh according to any of the preceding embodiments, wherein the integral metal mesh has a length measured in a direction perpendicular to the down roll direction of more than 1.00 m.

  PM28 The integral metal mesh according to any of the previous embodiments, wherein the integral metal mesh has a length measured in a direction perpendicular to the down roll direction of more than 2.00 m.

  PM29 The unitary metal mesh of any of the preceding embodiments, wherein the linear strands and the intersecting strands form a repeating pattern of voids.

  PM30 The unitary metal mesh of any of the preceding embodiments, wherein the linear strands and the intersecting strands form a repeating pattern of voids in the shape of a substantially parallelogram.

  PM31 The integral metal mesh of embodiment PM30, wherein the parallelogram has a major axis that is neither parallel nor perpendicular to the downroll direction and a minor axis that is neither parallel nor perpendicular to the downroll direction.

  An integral metal mesh according to any of the previous embodiments comprising PM32 copper.

  PM33 An integral metal mesh according to any of the previous embodiments comprising tin.

  The integral metal mesh according to any of the previous embodiments, comprising PM34 bronze.

  The integral metal mesh according to any of the previous embodiments comprising PM35 gold.

  The integral metal mesh according to any of the previous embodiments comprising PM36 silver.

  A solid metal mesh according to any of the previous embodiments comprising PM37 nickel.

  The integral metal mesh according to any of the previous embodiments, comprising PM38 zinc.

  A solid metal mesh according to any of the previous embodiments comprising PM39 iron.

  An integral metal mesh according to any of the previous embodiments comprising PM40 aluminum.

  The integral metal mesh of any of the previous embodiments, plated with PM41 nickel.

  PM42 The integral metal mesh according to any of the previous embodiments, plated with zinc.

  PM43 The integral metal mesh according to any of the previous embodiments, plated with tin.

  PM44 1. An integral metal mesh according to any of the previous embodiments, having a thickness of less than 1.800 mm.

  PM45. An integral metal mesh according to any of the previous embodiments, having a thickness of less than 0.800 mm.

  PM46. An integral metal mesh according to any of the previous embodiments, having a thickness of less than 0.400 mm.

  PM47. An integral metal mesh according to any of the previous embodiments, having a thickness of less than 0.200 mm.

  The integrated metal mesh of any of the previous embodiments, having a thickness of PM48 less than 0.040 mm.

  PM49. Integral metal mesh according to any of the previous embodiments, having a thickness of less than 0.020 mm.

  An integral metal mesh according to any of the previous embodiments having a thickness of PM50 greater than 0.010 mm.

  PM51 The integral metal mesh according to any of embodiments PM1-PM49, having a thickness greater than 0.030 mm.

  PM52 The integral metal mesh according to any of the previous embodiments, wherein the average distance between nodes measured along the linear strands is less than 4.000 cm.

  PM53 The integral metal mesh according to any of the previous embodiments, wherein the average distance between nodes measured along the linear strand is less than 0.900 cm.

  PM54 The integral metal mesh according to any of the previous embodiments, wherein the average distance between nodes, measured along the linear strand, is less than 0.450 cm.

  PM55 The integral metal mesh according to any of the previous embodiments, wherein the average distance between nodes measured along the linear strand is less than 0.200 cm.

  PM56 The integral metal mesh according to any of the previous embodiments, wherein the average distance between nodes, measured along the linear strand, is greater than 0.030 cm.

  Various modifications and alterations of this disclosure will become apparent to those skilled in the art without departing from the scope and principles of this disclosure, and this disclosure is unduly limited to the exemplary embodiments described hereinabove. It should be understood that it is not.

Claims (24)

An integral expanded metal mesh having a down roll direction, the mesh being
a) a plurality of linear strands that are substantially parallel to the down-roll direction;
b) a plurality of intersecting strands intersecting the linear strands at a node,
The integral expanded metal mesh is an integral expanded metal mesh whose length measured in the down-roll direction is more than 3.00 m.   The integral expanded metal mesh of claim 1, wherein the linear strands are parallel to the down roll direction with an angular tolerance of +/− 10 ° over the entire length of the mesh.   3. The integral expanded metal according to claim 1, wherein the linear strands are parallel to the down-roll direction with a net angle tolerance of +/− 10 ° accumulated over the length of the mesh. mesh.   The integral expanded metal mesh according to any one of claims 1 to 3, wherein the integral expanded metal mesh has a length measured in the down-roll direction of more than 8.00 m.   The integral expanded metal mesh according to any one of claims 1 to 4, wherein the integral expanded metal mesh has a length measured in the down roll direction of more than 900.00 m.   The integral expanded metal mesh according to any one of claims 1 to 5, comprising a metal selected from the group consisting of copper, tin, gold, silver, nickel, zinc, iron, aluminum, and alloys thereof.   The integral expanded metal mesh according to any one of claims 1 to 6, having a thickness of less than 1.800 mm and greater than 0.010 mm.   The integral expanded metal mesh according to any one of claims 1 to 7, wherein an average distance between nodes measured along the linear strand is less than 4.000 cm and more than 0.030 cm.   The integral expanded metal mesh according to any one of claims 1 to 8, which is an integral expanded metal mesh.   A composite material comprising: c) the integral expanded metal mesh according to any one of claims 1 to 9; and d) a polymer matrix.   The composite material according to claim 10, wherein the polymer matrix is an uncured curable resin or a partially cured curable resin.   The composite material according to claim 10 or 11, wherein the polymer matrix is an epoxy resin. e) Woven textile scrims,
f) non-woven fiber scrim,
The composite material according to any one of claims 10 to 12, further comprising one or both of the following.   The composite material according to any one of claims 10 to 13, which is a sheet material having a thickness of less than 6.00 mm and greater than 0.020 mm. It is a manufacturing method of the integral expanded metal mesh as described in any one of Claims 1-9,
g) preparing a metal sheet having a down roll direction;
h) A step of simultaneously performing a cutting step in the vicinity of the tip of the metal sheet and a bending step of the metal strand of the sheet using a tool disposed obliquely with respect to the down-roll direction of the metal sheet. The cutting step includes cutting a row of spaced apart slits in the sheet, and the bending step bends the thin metal strand of the sheet adjacent to each slit downward. The strand protruding in a direction orthogonal to the plane of the metal sheet,
i) advancing the metal sheet in the down-roll direction;
and j) repeating the step h) so that the spacing adjacent to the row of slits is a line substantially parallel to the down-roll direction of the metal sheet.   The tool includes a plurality of protrusions extending in a direction orthogonal to the sheet, the protrusions have a triangular shape or an arc shape, and the row of slits is a row of slits on the same line. Item 16. The method according to Item 15.   17. A method according to claim 15 or 16, wherein with each repetition of step h), the tool moves alternately between two positions relative to the lateral direction of the sheet.   17. A method according to claim 15 or 16, wherein, during each iteration of step h), the tool does not move relative to the lateral direction of the sheet. It is a manufacturing method of the integral expanded metal mesh as described in any one of Claims 1-9,
p) preparing a metal sheet having a down-roll direction;
q) cutting the sheet to form a slit metal sheet having a plurality of slit rows spaced apart from each other, the slit rows being in the down-roll direction of the sheet The step directed obliquely and adjacent to a row of slits is a line substantially parallel to the down-roll direction of the metal sheet; and
r) stretching the slit metal sheet in a direction not parallel to the down-roll direction of the metal sheet to form an integral expanded metal mesh;
Manufacturing method.   The method of claim 19, wherein the rows of slits are collinear rows of slits.   The step of preparing a metal sheet having a down roll direction includes the step of preparing a roll of a metal sheet having a down roll direction parallel to a long side of the roll-shaped metal sheet. The method according to any one of the above.   The method of claim 21, which is a continuous process by roll. An integral metal mesh having a down roll direction, the mesh being
a) a plurality of linear strands that are substantially parallel to the down-roll direction;
b) a plurality of intersecting strands that intersect the linear strands at a node;
With
The integral metal mesh is an integral metal mesh having a length measured in the down roll direction of more than 3.00 m.   24. The integral metal mesh of claim 23, wherein the integral metal mesh has a length measured in the down roll direction of greater than 900.00 m.

Images