SK12298A3 - Grid block material - Google Patents

Abstract

The description relates to a structural material having the configuration or form of a wire grid. The structural material can be made by first winding a continuous wire on a loom structure. Once the wire has been wound into an array of parallel wires, it is secured in place and separated into segments. The segments are then arranged in a frame. The frame arranges the segments at relative angles so that they form a matrix or network or sieve. In the final production step, the wires are welded together, e.g. in a forging press. Alternatively, the material may also be produced by first securing wire segments in a pair of frames and then welding them together. The structural material of the invention can be used alone or in layers to form a multi-layer material.

Description

Technical field

The present invention is based on U.S. patent application Ser. No. 08/035111, filed March 18, 1993, as well as another related application filed with respect to the above.

The invention relates to structural wire materials and methods for their manufacture. More specifically, the present invention relates to a constructional or building material having a multidimensional grid structure and a method for producing the same.

BACKGROUND OF THE INVENTION

In the field of material science, the main goal of the past few years has been to find lighter and stronger material. Currently, research in this field has focused primarily on the use of metals, plastics and ceramics. This research has led to improvements in existing technologies. In addition, it has brought some new methods and materials to help meet the above-mentioned engineering and economic requirements of modern society.

In the near past, research in the field of material science has concentrated, at least as regards the strength-to-weight ratio characteristics, on hydrocarbon-based polymers and the corresponding chemical process. Although the materials and methods of making them based on this research under selected conditions are both advantageous, useful or efficient, they usually do not relate to the problem itself and do not improve higher order structures. Furthermore, the repetition or reproducibility of metallic materials and their mechanical characteristics using carbon-based chemical formulation technology has remained the target of many of these materials and methods of making them. As a result, many of these materials show only a nominal improvement compared to the much more accessible metal construction materials or building elements.

SUMMARY OF THE INVENTION

It is therefore an object of the present invention to provide a low-strength, high-strength construction wire material.

The essence of the construction material according to the invention is that it is made of a wire mesh. Usually the wire grid is composed in the form of pyramids uniformly folded into a three-dimensional arrangement. Each pyramid consists essentially of eight wire segments that are interconnected at their intersections. The wire segments are part of a continuous wire. Although the structure of the material is such that it looks solid or strong at first glance, the fact is that it consists of a three-dimensional mesh of fine wires. These wires are usually made of brass or stainless steel. Preferably, the material is made of structural parts having a diameter of about 0.1 to 8.5 milligrams (0.005 to 0.1 inches) and are about 0.768 to 8.886 millimeters (0.03 to 0.09 inches) long. However, the material of the present invention is by no means limited to these diameters or lengths. In particular, the term wire in the sense of the present invention does not only refer to metal wires but includes all kinds of elongated fibers, regardless of the material from which they are made, and the only true intention of this term is to limit the choice of material here. However, even for mechanically less rigid materials than the aforementioned metal wires, however, the structure of the invention brings a clear improvement in the mechanical strength of the grid structure with respect to weight when the material is compared to known structures, for example in the form of a homogeneous solid material. Likewise, the preferred range of wire diameters indicated can be simply exceeded or reduced, up to 10x. Extremely stable but lightweight and thin-walled parts can be produced with very thin wires in the diameter range of 10 µm to 850 µm.

The material made of the steel wire of the present invention has approximately one fifth of the density of normal steel, but has comparable strength. These characteristics are caused by a number of factors. For example, the forces acting on the material are transmitted in the same way as the forces in the net or support structure with conventional dimensions. Furthermore, the small cross-sectional area of the wires leads to a large surface to volume ratio. In addition, the insulation of the elements reduces the progression of cracks or other defects through the material and also contributes to uniform distribution or load transfer. Finally, the small cross-sectional area of the wires used to produce the material, preferably with a diameter of 0.25 millimeters (0.01 inches), results in an excellent strength characteristic due to the small grain size of the wires, which prevents cracks from passing through the material.

In the most general form, the essence of the invented material is that it consists of a three-dimensional lattice structure, where initially the interest does not fall too much on the chemical or physical properties of the material being used. The invention is developed from a balance sheet which provides a structure of structural material that provides the most favorable ratio of stiffness or bending strength to the weight of the structural material. The components, i.e. the wires from which the entire structure is composed, should of course have good tensile and compressive strength. Here, the term wire does not necessarily mean metal wire, but may also consist of a plastic wire or a natural fiber wire that is correspondingly welded or glued together to each other. In fact, it is possible to achieve higher strength with metal wires, but on the other hand, using plastic or natural fiber wires, extremely low weights can be achieved, while the structure still has sufficient strength, but this weight is not a corresponding metal wires structure capable of to reach.

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The method of the invention ensures that at least three groups of wires or fibers (including non-metallic materials) are placed in parallel in each group and are placed one over the other and relatively aligned with each other at an angle of 10-90 °, these groups of wires or fibers. The other fibers are interconnected in their intersection points, preferably by welding or gluing. In the case of a flat or even material produced in this way, the groups of three wires or fibers form a structure of triangles adjacent to each other in such a way that they cover the entire surface. This structure may be folded along parallel lines running at equal intervals, with wires of one group of parallel wires preferably defining a fold line. Without intending to limit the invention, but merely to simplify the description, the term wires, which also cover non-metallic materials, or means non-metallic materials in a similar manner, will be given below.

In a preferred embodiment, the triangular grid, formed from three groups of parallel wires, is alternately folded along adjacent wires from one group in a accordion-like manner. The grid thus folded appears from the side in a zigzag shape, with two parallel planes of fold lines, referred to herein as upper and lower planes, for better differentiation.

Depending on the structure of the triangular network, quite specific angles of folding are preferred. The fold angle here means the angle between two planes that intersect in one of the plane's fold lines and extend through two fold lines of another plane adjacent to them.

In particular, there is a preferred variant of the invention in which the fold angle is selected such that the distribution of adjacent fold lines in the upper plane as well as the distribution of adjacent fold lines in the lower plane is exactly the same as the inter-node distance of intersections of wires along the fold line or between folds and intersections, there are sets of smaller integers in relation to each other. This allows that in particular two such folded grids can be placed one on top of the other, rotatable 90 'to each other, all intersections, or at least in any case a large number of intersections in the lower plane of one lattice, can coincide with the intersections of the upper plane of the second lattice. and thus a connection can be established at these intersections. This results in a particularly stable three-dimensional structure.

A particularly preferred embodiment of the invention has flat gratings that are composed of equilateral triangles, i.e., three groups of wires intersect each other, forming an angle of 60 'together, this arrangement is usually formed such that a third group of parallel wires extends exactly along the intersections of the other two groups but this is not necessarily the case.

In such an embodiment, an angle below which the spacing of adjacent fold lines of one plane coincides with the spacing of the intersections along the fold lines of about 51.3 ° is preferred.

Another embodiment of the present invention, which differs from the above, and may be preferred for particular conditions of use, consists of three groups of wires that are aligned relative to each other so that non-equilateral but isosceles triangles are formed in which there are two shoulders quite clearly distinguishable longer than the base. This means that the two wire groups intersect each other at a slightly more acute angle than 60 °, while the third wire group forms an angle greater than 60 "with the first two and passes through the intersections of the first two wire groups. The third group of wires thus produced also forms a fold line where, as in the embodiment described above, the three-dimensional structure of the pyramids is formed due to the fold, only two opposing bases are missing. In this preferred bending angle embodiment, the resulting pyramids are higher and have a sharper angle, and the upper and lower planes are spaced apart from each other as in the above-mentioned embodiment of the invention, which was composed of equilateral triangles. Likewise, in this case, two lattices, which are perpendicular to each other, may be placed one on top of the other by covering their intersections and being connected when the above-mentioned preferred fold angle is maintained, depending on the exact form of the triangles, of which the corresponding flat grid is folded. By combining two such folded grid structures placed on top of each other, the desired pyramids are also formed, with the base all around. Regardless of the folded gratings to be placed on top of each other, the flat gratings may be welded or glued equally together with the folded gratings, so that the flat gratings correspond exactly to the intersection structures of the intersections of the upper or lower plane of the folded grid. In the triangular grid described above, due to the folding of the lower and upper planes, in each case rectangular grid structures are formed and, using the preferred fold angle, also the square grid structures. In particular, according to the invention, the structure may also be formed from several layers of folded gratings, between which optionally also matching layers of flat gratings, for example rectangular gratings, may also be inserted. If the flat lattice is positioned between two folded lattices, a 90 ° rotation of the folded lattices can be eliminated from each other, and in this case it is not necessary to maintain the preferred folding angle.

An embodiment of the invention also relates in particular to the production of input components, namely flat gratings, which are then optionally folded and joined together in several layers in order to form a final block of material.

To simplify the production of the flat gratings according to this embodiment of the invention, it is possible to use a flat or equally mesh material, for example a metal sheet, from which parts of the material are then removed for example by cutting, etching, drilling or otherwise. The remaining portions of this lattice material are considered to be wires forming the lattice and are connected to each other in one piece of material, in accordance with an embodiment of the invention described above.

Compared to the above-described embodiment of the invention, this latter embodiment is particularly characterized by the following advantages:

1. Resulting grid It is evenly thick over the entire surface, it is equally at the points of intersection of wires the material is as strong as between these intersections (or knots).

2. The manufacturing step eliminates the step of placing several groups of parallel wires in layers on top of one another, forming their intersections with each other and joining them together at these intersections. The connection is already established by using one cohesive starting material.

3. Wires or individual pieces of netting material that remain after cutting or etching the corresponding holes in the netting material do not necessarily run along continuous straight lines, but may rather be made at an angle, relative to each other, to form a planar lattice in points of intersection. Therefore, these intersection points do not necessarily have to be arranged in groups of three parallel lines in which the groups of three intersect each other, but the slightly more complex structures are equally conceivable, in fact the individual intersections can in fact be placed along a parallel straight line where they are needed. groups of more than three parallel lines to describe the position of all intersections, and / or where the intersections of the intersection lines are comparable to materials made of groups of three parallel wires, smaller or larger. Correspondingly more complex structure For example, considering that from a lattice of isosceles triangles, two of the wires of a group intersecting each other do not lead exactly in a straight line, but rather along a zigzag line, with an angle change in each case at the intersection in which adjacent wires of the same group in each case are guided at an angle exactly in the opposite direction, so that for a given wire of one group only every other wire runs parallel, along the same zigzag line. The triangle network resulting from the above manufacturing process is then composed not of isosceles triangles, but rather of rectangular triangles, whose peaks on a larger scale may be symmetrical than a lattice of isosceles triangles.

The wires or fibers of which the grid made of mesh material is composed need not necessarily have a constant cross-sectional area over its entire length, but rather may be wider and therefore also reinforced at, for example, intersection points.

In addition, there are a number of possibilities for developing a flat grid or mesh structure, but these must be developed to have parallel intersection lines along which the mesh material is folded so that, after folding, these intersection lines define two parallel planes and can occur in these planes. for connection to other grids having a comparable intersection structure in the connection plane. A lattice structure having identical symmetry and equal intersection distances is considered comparable here, so that the intersections of adjacent planes of the two lattices to be joined can be positioned so that they coincide with one another or that have at least such symmetry and such the distance between the intersections that at least a reasonable proportion of the intersections of adjacent grids, i.e. at least 10%, can be positioned so that they coincide, and thus the grids can also be connected to each other. This, of course, applies analogously to the case where the intersections of adjacent grids are not joined, but the intersection of one grid is connected to the cross piece (wire between two adjacent intersections) of the other grid. The special conditions of symmetry and spacing must also be fulfilled here, so that the joining points are distributed as uniformly as possible over the entire joining plane, so that the forces acting on the material during subsequent use are equally distributed and dispersed.

Additionally, two methods for producing a flat lattice, which is composed of isosceles triangles and producing corresponding folded lattices, are described below.

According to a first method, the method of manufacture of the present invention comprises a design of a device capable of receiving a series of sliding rollers and a frame of a state in which the rollers can be placed. Next, fine wires are placed in the frame of the state and then the fabric. After the match, the wires are welded together. The net resulting from this process, or the mesh material, may be used in the desired manner, or may be shaped as desired to produce a corrugated material. In an alternative embodiment of the method according to the invention, the material according to the invention can be produced in elongated sections using unified fastening and welding superstructures. These elongated sections may then be corrugated or otherwise shaped as desired. The individual steps of these production methods of the present invention are set forth in detail below.

Now, with respect to the first manufacturing method according to the invention, several different slide rollers are fixed to the frame or cloth frame during the first step. This equipment is used to keep the wires under tension and in the correct position before welding. The drapery frame is essentially a flat circle that has three sets of opposing T-slot nets that are spaced at an ISO angular interval. The superstructure sliding rollers, which are dimensionally and dimensionally adapted to fit into the net or rails or the drapery frame, have rows of parallel grooves in order to grip the wires and keep them precisely in position. In the next step, a state frame is prepared that consists of three racks with grooves on a rotating trigonal platform. More precisely, the frame of the state is prepared to comprise three posts or stands having positioning surfaces on which the sliding rollers are fixed before the wire is pulled from the spool. While the coil frame or the frame of the state and therefore the racks are rotating, the wire still runs downwardly through the grooves in the sliding rollers, so that after one revolution of the wire it leads to the next deep groove.

Once the wire is arranged on the frame of the condition or coil, the wire is then separated along the sliding rollers.

Then the sliding rollers are fixed to the preformed frame so that a wire net or matrix is formed. The intersections of the wire matrix, i.e., the points at which the wires extend over one another or lie one over the other, are then connected to each other using a forging press. The forging press supplies heat and pressure evenly to all connections to achieve a weld at each intersection. Once only with each other, the pulleys and the drapery frame can be punched using the method all intersections of the material are selected from sliding

The flat material thus according to the invention can be used in insulation as a building material. As an alternative, the resulting material may be bent or otherwise formed using a press, die, or through the toothed rollers to form a corrugated grid material, or a grid material in the form of a accordion. The latter type of material can be stacked alternately with and attached to the flat material lattices, and thus a three-dimensional thicker construction material can be produced.

At the beginning of an alternative method according to the invention, a set of wires is placed on the second retainer frame. Then the wire is placed on the first frame retainer. The first and second retaining frames are then displaced such that they are facing each other and the wires of the second retaining frame are positioned at a relative angle of approximately 60 'with respect to the wires of the first retaining frame. At the intersections, the wires of the second retaining frame are welded to the wires of the first retaining frame. Welding can be performed wire by wire individually or in groups as desired. The weld is completed, the wires are stretched 13 in the second retainer frame forwards so that the wires in the first retainer frame can be moved to the adjacent groove. Then the second wire is placed in the first retaining frame and the welding process is repeated. This process continues until the substructure with the required dimensions is completed, from two sets of welded wires.

In a further phase of this alternative method of producing the material of the present invention, the third set of wires is welded to a substructure formed from two wires as described above. Here the wire is placed in the first retaining frame. The first holding frame and the second holding frame are then moved to a position where they lie opposite each other so that all the wires are aligned at a relative angle of approximately 60 °. This means that a series of isosceles triangles is created. At the intersections, the wires are welded to each other. As mentioned above, the welding may be performed wire by wire or in groups of wires, as desired, a finished, fabricated frame material.

When the welding of the wires is released from the retaining material, the material produced using the alternative method of the invention can also be used in the insulation itself as a construction material or construction material. Optionally, the material so produced may be bent or otherwise formed using a press, die or by passing through the toothed rollers to form a wavy grid material, or a toothed or serrated grid material. The latter material may alternatively be stacked with flat material lattices, associated with them to form a thicker three-dimensional material.

In a further method of making a grid material according to the invention, which is not limited by an angle of 60 'between the groups of wires, a set of parallel wires is clamped in the clamps, these clamps can be drawn through the welding device parallel in their longitudinal direction. The corresponding device additionally comprises guide and / or fastening devices which can hold the first group of wires in a parallel position and further comprise further guide and / or fastening devices which can hold the second group of wires in a parallel position which are guided at an angle with respect to the first group of wires, this angle may be between 10 'and 90'. Finally, the corresponding device also has a third group of guide elements or fasteners by means of which the third group of parallel wires are aligned so that they are guided with respect to the first and second groups of wires at an angle which can vary between 10 'and 90'. at the same angle to the first group of wires which the second group also forms with the first group. Here, the guide elements or fastening devices are arranged such that the three groups of wires in each case have common intersections. The welding may be performed sequentially, that is, first between the wires of the first and second groups and then between the wires of the third and second groups, but may also be performed simultaneously with all three groups or individual wires. Then the wires are picked up from the corresponding guide elements or fastening devices and offset by a distance that corresponds to the working range of the welding device.

In this way, groups of wires can also be arranged simply in layers one over the other, if desired, but they can also be interwoven with each other, but of course the manufacturing process is problematic.

By virtue of the principle of the present invention, not only flat structures but also structures that are curved three-dimensionally, such as pipes or similar structures, must be produced. To produce this, the folded grid described above can be produced first, then bent into the shape of a pipe or a portion of a pipe. In this case, however, there is a connection with another folded grid or other structure of one or two flat grids on the inner and / or outer side of the folded grid, bent into a tube shape after folding. In this particular case, care must be taken that, because of the curvature, the distribution of the intersections on the inside of the bent folded grid is different from the curvature of the outside. Advantageously, flat gratings and folded gratings are produced with different grating dimensions, which can be accurately given to a given tube diameter so as to coincide with the intersections of the folded grating. Therefore, it is also preferable to produce unique fixed diameter pipes on which a large number of matching folded grids and flat grids can be provided.

Other general and specific objects of the invention are in part apparent and will be elucidated below.

The invention also relates to a method and apparatus for manufacturing, wherein the method of making comprises steps, the apparatus having certain characteristics, combinations of components and arrangement of components that are designed to meet the steps of the method as described by way of example below. all of which is included in the scope of the appended claims.

List of figures in the drawings

A full understanding of the nature and purposes of the invention will be possible by reference to the precise description and reference figures in the drawings, in which:

Fig. 1 shows a perspective view of an embodiment of a construction material according to the invention,

Fig. S shows an enlarged plan view of a cut-out of constructional or building material, in the embodiment of the invention of FIG. 1

Fig. 3 shows a perspective view of another embodiment of a construction material according to the invention having a corrugated or grooved cut structure;

Fig. 4 shows an exploded perspective view of another embodiment of a construction material according to the invention having alternating layers of the embodiment of FIG. 1 to FIG. 3

Fig. 5 shows a perspective view of the embodiment of the construction material of FIG. 4, here in the assembled state,

Fig. 6 shows a perspective view of an embodiment of a frame or drapery frame that is used to produce a constructional maverial according to the present invention, wherein a first material manufacturing method is used wherein the sliding rollers and wire fibers are forged in position;

Fig. 7 shows a perspective view of an embodiment of a state frame or coil frame used to produce a construction material according to the present invention, wherein a first material production method is used in which wires are woven into a section of a slide roller;

Fig. 8a shows a plan view of a first retaining frame that is used to produce a construction material in an embodiment of the invention, wherein an alternative method of making the material is used;

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Fig. 8b shows a plan view of a second retaining frame that is used to produce a construction material in an embodiment of the invention, wherein an alternative method of making the material is used;

Fig. 9 shows a flat lattice consisting of isosceles triangles with a small acute angle,

Fig. 10 shows schematically a change in structure associated with the folding process;

Fig. 11 shows a plan view of a folded grid with a preferred angle of deflection so that the intersections of one plane form a square grid,

Fig. 12 is a section of FIG. 11, here in perspective, and finally

Fig. 13 shows a grid made of a primary mesh material.

DETAILED DESCRIPTION OF THE INVENTION

Referring now to FIG. 1 to FIG. 8, in which the same position numbers refer to like parts, and in which the construction wire material 10 which is realized by the present invention can be seen. The structural wire material 10 is made of a grid or network of fine wire segments 18 which are joined together at intersections 14. The fine wire segments 13 are the individual parts of the continuous wire 16.

As shown in FIG. 1 to FIG. S, the structural wire material 10 is characterized by a grid of fine wire segments 18. As shown in FIG. 1 to FIG. 3, the construction wire material 10 may be flat or corrugated or serrated in its cross-section, depending on the intended technical use. In the larger, more complex embodiment of the invention illustrated in FIG. 4 and FIG. 5, the structural wire material 10 has a multilayer structure that consists of pyramids 18 uniformly stacked in a three-dimensional configuration. Each pyramid 18 is comprised of eight wire segments 18 which are connected to each other at intersections 14. In all of these embodiments, the wire segments 18 are typically made of brass, stainless steel or EDM wire. Preferably, the fine wire segments 18 have a diameter of between 0.185 to 0.354 millimeters (0.005 to 0.01 inches). In addition, the wire segments 13 are typically 0.5 to 3.5 millimeters (0.03 to 0.1 inches) long. The currently preferred wire segment material has a diameter of approximately 0.3 millimeter (0.08 inches) and is made of stainless steel.

The invention also relates to an alternative method of manufacturing a structural wire material 10). The first method utilizes a frame or cloth frame 88, and a state 86, which are described in more detail below. An alternative method of manufacturing the structural wire material 10 utilizes a first retaining frame 70 and a second retaining frame 78, as shown in FIG. 8a and FIG. 8b to produce the material of the present invention.

At the beginning of the first method of manufacturing the material of the present invention is a frame 88 which is designed to receive a set of sliding rollers 84. In addition, a state 86 is prepared in which the sliding rollers 84 can be positioned during initial weaving. During the next step of the method of manufacturing the construction material of the invention, the continuous wire 16 is fixed to be ready for weaving. The continuous wire 16 is then retracted to a state 86 and is woven as desired. After weaving, the wire or wires 16 are placed in the frame 88 and are connected to each other, usually by welding at the intersections 14 of the wire segments 18. The network or structure thus produced may then be used as desired or may be shaped as desired to further develop multilayer material. The individual steps of the procedure of the present invention are discussed in more detail below.

During the first step of the method of manufacturing the construction material of the present invention, the frame 88 and the sliding rollers 84 are fastened. 6 and FIG. 7, these devices serve to keep the wires or wire fibers 16 under tension and in the correct oriented position, prior to welding. Generally, the frame 88 is formed by a flat grid 88 having three sets of opposing rails or guides 50 having T-shaped slots 35. The rails 20 are fixed at angular distances or intervals of 180 '. This angle is thus chosen precisely because when there are three sets of sliding rollers 34 having wires or wire filaments 16 from which these wires are stretched, placed in the frame 88. the wire segments 13 extend over one another and form a plurality of equilateral triangles.

In each case, the sliding rollers 34 have a first pulley portion 58 with a first surface 23 having a set of parallel grooves 34 intended to receive the wires 16 and keep them in place. The second surface 37, which is located on the visible side of each sliding roller 84, is designed to be ready on the upright 38 of the state 46, described more precisely below. Each slide pulley 34 also has a second pulley part 36 that is designed to fit into the first pulley part 58. The second pulley part 36 is sized and shaped to fit into the wires when the weaving described below is completed. The first pulley part 33 and the second pulley part 36 can be connected, for example, by means of machine screws, bolts, and other connecting elements, of which the skilled artisan will be familiar in the art.

Next, a state 86, which is shown in FIG. 7 and which consists of three uprights 58 on a rotatable trigonal platform 40. Each upright 58 has a positioning surface 48 to which the first portion 38 of the sliding roller 84 is attached before the wire 16 is pulled into the state 86. Positioning surfaces 48 on the uprights 38 are designed to provide sliding rollers 84, or better, their surfaces 33, which are provided with grooves in an outwardly pivoted position. In operation, each of the second surfaces 57 of the first portion 38 of the sliding rollers 84 is positioned in contact with the surface of one of the uprights 38 in order to prepare the weaving state 36. The sliding rollers 34 may be attached to the uprights 38, for example, by using similar machine screws or other fasteners that are familiar to those skilled in the art.

In the next step of the method of manufacturing the construction material of the present invention, the state 86, and therefore the props 38, is rotated so that the wires 16 can be pulled over the grooves 34 of the slide rollers 84. In particular, the state 36 is rotated so that deeper grooves 54 of each sliding roller 84. This procedure continues until all slots 34 of the sliding roller 84 contain part of the wire 16. During weaving of the fibers of the wire 16, these are preferably held under tension by a force of about 0.0137 to 0.0588 N (0.05). up to 0.8 ounces). When this manufacturing method is carried out, a parallel array of wire or wires 16 is thus formed between all the uprights 38. When the wire is placed on a state 36 or coil frame in parallel configuration, then the second part 36 of each sliding roller 34 is placed on each first part 38 sliding pulleys. The wire 16 is then fixed in position for further processing. Then the wire 16 is separated. More precisely, the wire 16 is separated along the legs 58, for example using a welding flame. This procedure creates three independent sections 46 with a sliding roller 84 at each end of the wire section 48. The slide rollers 84 are then released from the positioning surfaces 48 and transferred to the frame 88.

In a further step of the method of manufacturing the construction material of the present invention, the slide rollers 84 and wire portions 48 are attached to the frame 88 and said wire portions 48 are connected to each other using a forging press. In particular, the sliding rollers 84 are disposed in the T-shaped slots 55 on the rails 30. Similar T-shaped slots 55, the sliding rollers 84 and said wire portions 48 are mounted on the frame 88 at a relative angle of 180. This arrangement provides a triangular grid Each of the triangles 50 has three intersections 14, together with the adjacent triangles 50. While all the wire segments 18 are correctly and precisely oriented, a forging press is applied to all intersections 14 suddenly the effect of thermal energy and force was developed. The use of a forging press is well known in detail to those skilled in the art. Preferably, the press provides approximately 50 pounds per square inch pressure and produces a temperature of up to 676 C (1850 F). The welding of the wire segments 18 occurs under vacuum. Once all the intersections 14 are connected to each other, the structural wire material 10 thus formed can be removed from the frame 88 and optionally from the slide rollers 84.

Fig. 8a and FIG. 8b show a first retaining frame 70 and a second retaining frame 78, which can also be used for an alternative method of manufacturing a construction material according to the present invention. According to FIG. 8a, the first retaining frame 70 has an approximately rectangular shape. A set of grooves 74 is formed in the surface 76 of the first retaining frame 70. It will be appreciated by one of ordinary skill in the art that the dimensions of the groove 74 are intended for the dimensions of the wire used to construct the material and the grid of the invention. The grooves 74 are distributed uniformly on the surface 76, at a distance from each other. Generally, the distance between the grooves 74 is determined by the desired characteristics of the material produced and the grid. Typically, the grooves 74 are spaced from each other by 0.75 to 1.8 millimeters (0.03 to 0.07 inches). Preferably, the grooves 74 are spaced approximately 1.87 millimeters (0.05 inches) from each other, and the grooves 74 extend parallel. The slot 78 is made at the edge 80 of the frame 70 to provide access to the welding electrode (not shown).

According to FIG. 8, the second retaining frame 78 has a polygonal shape with at least two sides 88 and 84 that are arranged at an angle relative to each other. This angle between the sides 88 and 84 of the second retaining frame 78 is selected such that the wires when arranged in the frame 78 are aligned at approximately 80 'relative to the wires located on the first retaining frame 70. The second retaining frame 78 similarly has a set grooves 86 that are cut into one of its surfaces 88. Here, too, those skilled in the art will recognize that the dimensions of the grooves 86 are determined by the dimensions of the wire used to construct the material and the grid of the present invention. The grooves 86 are spaced at a uniform distance from each other on the surface 88. The distance 84 between the grooves 88 is determined by the desired properties of the material being produced and the grid. Typically, the grooves are approximately 0.75 to 1.8 millimeters (0.05 to 0.07 inches) apart. Preferably, the grooves 86 are spaced approximately 1.87 millimeters (0.05 inches) from each other, and the grooves 86 extend parallel. The flange 90, which is held in position by the screw 98, extends over a portion of the surface 88 of the second retaining frame 78. In use, the flange 90 cooperates with the screw 93 so as to secure wires located in the first retaining frame 70.

At the beginning of an alternative method of manufacturing the construction material of the present invention, the first set of wires is placed in the grooves 86 of the second retaining frame 78. Once these wires are positioned, the flange 90 is elongated therethrough and secured by a screw 98. The first 70 and the second retaining frame 73 are then brought into contact with each other so that the wires overlap and are aligned at a relative angle of approximately 60 ° to each other. Preferably, the wires that are held in the second retainer wound 73 extend beyond the wire that is held in the first retainer frame 70. The wires are then welded together at their intersections. Welding can be done wire by wire or in groups, all according to funerals.

When the welding of the wires that are held in the first 70 and second 73 by the frame retainer is complete, the partial material structure is shifted such that the wire in the frame 70 now rests in a groove away from the edge 80 or in a minor groove. Then, the new wire is placed in a groove 74 that is closest to edge 80 and the welding process begins again. In this way, the following wires that are held in the first retainer frame 70 are placed on the wires held in the second retainer frame 78. In a further phase of this method of manufacturing a construction material according to the invention, a third set of wires is placed on the wire substructure of the method described. To carry out this procedure, it is necessary to reposition the wire in the groove 74 that lies closest to the edge 80 of the frame 70. The first 70 and second 78 retaining frames are now displaced so that they lie adjacent to each other so that all the wires overlap each other and are arranged so as to clamp a relative angle of approximately 60 'to each other. The wires are then welded together again at their intersections. Welding can be done wire by wire or in groups, all as needed.

When the welding of the wires is completed, the structural wire material 10 of the present invention is removed from the frames. The structural wire material 10 can then be further processed according to the requirements.

The structural wire material 10) produced by the method of the present invention can be used in the insulations as indicated in FIG. Optionally, the structural wire material 10 may then be crimped or folded as shown in FIG. 3, for example when using a press, die, or by pulling over the toothed rollers to form a corrugated or bent grid. Preferably, the structural wire material 10 is folded or waved, as shown in FIG. 3, manufactured in such a way that the flat construction material is passed through a roller press. The roller press has a substantially flat projecting portion and a corrugated return portion. The undulating return portion contacts the flat projecting portion tangentially along one line. In operation, the structural wire material 10 is then bent along the contact line between the protruding and return portions of the press. This structure is preferred because it allows the construction wire material 10 to be pulled together while being bent or corrugated.

The structural wire material 10 so produced using the method of the present invention can also be used to produce a larger, multi-layered structure as indicated in FIG. 4 and FIG. 5. In this embodiment, alternating layers of the flat construction wire material 10 of FIG. 1 associated with the corrugated or folded structural wire material 10 of FIG. 3. In order to produce this material, it is necessary that the layers are first stacked on top of each other, as shown in FIG. Further, the loose structural wire material 10 is placed in a forging press and is welded according to the method described above in connection with the method of forming the individual sheets of structural wire material 10.

The following is an illustrative, non-limiting, example of a manufacturing material manufacturing process according to the present invention.

Example 1

In any case, at the beginning of the manufacturing process, part of the wire was inserted into grooves that were cut in the surface of the second retaining frame (Fig. 8b). One wire was placed in the first groove of the first retaining frame (Fig. 8a). The wires housed in both frames were made of stainless steel with a diameter of 0.8 millimeter (0.08 inches) manufactured by the All Stainless Company of Hingham, Massachusetts. Further, using a straight edge, the aligned ends of the wires were placed in the second retaining frame by extending each wire approximately 0.864 millimeters (0.01 inches) beyond the edge of the frame. The wires located in the second frame retainer were then brought into contact with one wire located in the first frame retainer. In particular, the wires have been oriented such that the wires in the second retainer frame have been guided at a relative angle of 80 relative to the wire disposed in the first retainer frame.

In the next step of the manufacturing process, an electrode was contacted with the wires in the second frame retainer as well as with one wire in the first frame retainer. More precisely, an electrode was placed at each intersection to exert a force of 88.88 N (6 pounds) at each wire contact point. The electrode was coupled to a current source capable of supplying a regulated percentage of nominal current ranging from 1 to 90% in 1% increments, namely a controlled frequency of 60 Hz cycles (each cycle of approximately 16 ms), ranging from 1 up to 70 cycles per step 1 cycle. Thus, a current of 66% of the standard nominal current was fed to this source at each intersection point within a cycle. This process was repeated until all intersections were welded to each other. In the final stage of the process, the partial structures of the first and second wires were repositioned in the second retaining frame and then the third retaining frame was placed in the first retaining frame. At each intersection, the electrode was again placed in contact with the wires, so that it again exerted a force of 83.36 N (5 pounds) on each contact point of the wires. The source was supplied with a current of 6S% of the standard nominal current to all intersections in one cycle. This process was repeated until all intersections were welded to each other. It can thus be seen that the invention achieves in an efficient manner the objects described above, which are obvious among others from the above description. In particular, the present invention provides a high-strength construction material having a low weight and an equally effective method of manufacturing it.

It is clear that changes to the construction of the invention may be made as well as changes to the operating or production sequences may be made without departing from the scope of the invention. Accordingly, it is clear that the foregoing description, as well as exemplary embodiments and figures in the drawings, are by way of example only and do not limit the invention in any way.

It will also be understood that the following claims are all encompassed by the invention described herein and are intended to cover the specific features and the like of any disclosure of the scope or field of protection of this invention, which may vary somewhere between depending on the manner of expression.

Fig. 13 shows schematically an example of a cut-out of a flat mesh material which has been given by cutting or etching the shape or structure of a regular triangular grid. The areas taken from above have a plan view of equilateral triangles, rounded at the tops, so as to form intersections which are reinforced with respect to the fibers forming the intersections. Possible lines of folding or folding of such a grid are indicated by a dashed line.

It will be appreciated that the indentations in the mesh material may have essentially any desired shape and arrangement, so that not only all structures that can be formed with a plurality of parallel wires but also much more complex grid or mesh structures can be formed. Continued with such a flat grid or net, it may be folded and associated with similar lattices, or other folded or flat lattices, and stacked in layers to form the entire block of material.

In FIG. 9 shows a cut-out of a flat grid on which three groups 7, 3 and 3 wires are aligned parallel to each other, the groups 8 and 3 of wires intersect each other at an angle of approximately 40 "and both form with the third group 1 wires in each 70 '.

If a folded grid is made of this group, the fold line will preferably extend along the first wire group 1, and the other wire groups 3 will then form a pyramid structure.

In FIG. 10 shows the effect of the folding process on the structure in the upper and lower planes 4 and 4 'of the folded grid.

First, FIG. 10 in the lower left corner is a flat lattice that is made up of equilateral triangles.

The wires from the group 1 and 1 'of the parallel wires are selected as fold lines. The folding may be carried out by means of rollers, a bending device, or by means of presses. In the upper left corner of FIG. 10 is a side view of the folded grid in the diagram. The wires from group 1 of wires define the upper plane 4 of the grid and the wires from group 1 'of parallel wires define the lower plane 4' of the grid. In FIG. 10 is also drawn in the upper left corner

It is defined as the angle enclosed by planes whose intersections form one fold line and these planes extend through each of the adjacent fold lines of another plane.

the angle of deflection α, which is two intersecting

FIG. 10 shows a folded grid in plan view. For better comparison with the flat grid, four grid points are highlighted on the wires from both the group and the wires that define the upper plane 4 by a small circle. Equally, the ringed points of the grid are also seen to the right in the folded grid, where their distance in the direction of the fold line identical to the wires of both the group and the wires does not change in any way, unlike the distance perpendicular to the line formed by wires of groups 1 and 12 wires has changed. In fact, this horizontal distance in the folded grid only depends on the angle of deflection a. For a flat lattice consisting of equilateral triangles and having a hexagonal structure, it is possible to achieve, at an angle of deflection and equal to approximately 51.3 ', a situation in which the horizontal distance spacing of the grid points indicated in FIG. 10 as a, that is, the spacing of adjacent fold lines of the same planes 4 and 42, fits with the spacing of the intersection b of the grid intersections along the lines formed by the wires of groups 1 and 12 wires. Such a case is illustrated in FIG. 11th

In this FIG. 11, it can be seen that after bending at a preferred angle and the intersections of the upper plane of the grid, they form a square grid, and that the intersections of the lower plane of the grid, in some cases encircled, also form an identical square grid. For a better understanding of the three-dimensional structure, the lower grid fold lines are indicated by a dashed line and the upper grid fold lines, like the pyramidal side edges, are solid lines.

The area 5 in FIG. 11 is again shown in perspective in FIG. 18. In this FIG. 12, a total of twelve pyramids can be seen in total, the peaks of which are connected to each other, using wires from group 1 of parallel wires, while wires from group 12 of parallel wires in the lower plane 4 'in each case define parallel side edges of the lower plane of the pyramids. In this form, the structure is only resistant to bending in one direction and has a high resistance to bending about an axis that extends perpendicular to the fold lines in the plane 4: or in the plane 4 '. Initially, however, this grid offers little resistance to bending about an axis parallel to the fold lines, due to the fact that on the pyramids of their lower edge extending horizontally in FIG. 12, still missing. But if we take an identical folded grid, we turn it 90 ° with respect to the one shown in fig. 11 and FIG. 12, and then placed on the first grid, its fold lines then extend exactly perpendicular to the fold lines formed by the wires of groups 1 and 1 of the parallel wires of the drawn grid, and the two grid may be positioned relative to each other so that the intersections forming the vertices or the lower corners of the pyramid, exactly match. When the grids are welded together in this form, the peaks or peaks in the base of the pyramid are also connected to each other in a horizontal direction and then form a structure that is highly resistant to torsion stress. Here, several layers can be welded on top of each other, alternately interlaced with a 90 ”rotation on top of each other. Either a simple flat square grid having the same grid dimensions as the span of the pyramid base peaks may be welded to the corresponding lowest plane, or there may be welded only a group of parallel prestressed wires that run perpendicular to the fold line given by wires from group 1 'parallel wires. and have the same spacing from each other as the lines given by the wires of the group 1 'of parallel wires (and therefore, like the lower peaks of the pyramids), on the lower plane 4' at the intersections.

Iο Certainly, of course, it also occurs with the tops of the topmost pyramid of such a block grid, which consists of several layers, with intersections of the pyramids already connected together in one direction by wires of group 1 parallel wires, which are also interconnected horizontally with a square grid wires. At the same time, it should be pointed out that the lower peaks of each of the pyramids simultaneously form the same peaks of the inverted pyramids as can be readily as follows. is done by joining the lower peaks of the pyramids.

Of course, when several layers of such folded lattices are connected to each other, it is important to precisely align all the intersections of the lattice, so that the intersections in the adjacent planes 4 and 4 'of the adjacent folded lattices lie exactly opposite each other. The folding of the grid must be carried out in a previously accurate manner. When two grids are precisely aligned with each other, in the case of welding only two grids, this welding can only be carried out by a forging press which acts on one side of the grille on tops of the pyramids. However, such a mode of operation is not quite possible with a higher structure of several layers. However, if the lattices are made very precisely and lie on each other equally very precisely, the welding can take place by means of electrodes having a large surface which abuts the two outer sides of the lattices and through which a corresponding sufficient current is fed into the lattices, the grids to each other at their contact points, which define a higher electrical resistance than the remaining material.

Of course, mechanical bonding technologies such as those known from the formation of semiconductor chips, for example by means of gold wires, are used equally.

Instead of or in addition to one or more of the flat grids, plates or foils may be attached by welding, gluing to the tops of the pyramids and the tops of the folded grids. This is especially true for the last outer layers or single or multi-layer gratings. The construction material of the present invention can then also be used in gas-tight or water-tight partition walls or containers.

Similarly, the intermediate grid spaces may be filled in the same way, independently of the surface covering, or even in addition to the surface covering, for example by using synthetic resin or other liquid, preferably curable, substances.

Claims (3)

Μ1Μ.-Φ IN A grid wire material, in particular of thin wires, having a first group (1) of wire segments (13), a second group (S) of wire segments (13) and a third group (3) of wire segments (18), these wire segments ( 18) and are welded together at intersections (14), at least two of the first group (1) of wire segments (18), the second group (8) of wire segments (18) and the third group (3) of wire segments (13) are guided at an angle of approximately 60 'relative to the other groups of wires, characterized in that the first group (1) of wire segments (13), the second group (S) of wire segments (18) and the third group (3) of wire segments (18) are fastened to each other so as to form a continuous array of triangular structures, said triangular structures being present in the form of sets of equilateral triangles. The grid wire material according to claim 1, characterized in that the first group (1) of wire segments (13), the second group (8) of wire segments (13) and the third group (3) of wire segments (13) are made of material. selected from the group consisting of brass, stainless steel and EDM wire. A grid wire material according to claim 8, characterized in that the material forming the first group (1) of wire segments (18), the second group (S) of wire segments (18) and the third group (3) of wire segments (1S) has a diameter in the range of about 0.0125 to 2.5 millimeters (0.005 to 0.01 inches). A grid wire material according to claim 3, characterized in that the material forming the first group (1) of the wire segments (12), the second group (2) the wire segments (12) and the third group (3) of the wire segments (12) have a diameter of about 0.2 millimeters (0.008 inches). A grid wire material according to claim 2, characterized in that the distance between the intersections (14) of the first group (1) of wire segments (12), the second group (2) of wire segments (12) and the third group (3) of wire segments (12). 12) is in the range of about 0.25 to 2.5 millimeters (0.01 to 0.1 inches). 8. A method of making a grid wire material, in particular of thin wires, characterized in that it comprises the step of preparing a ring-shaped frame and at least three sets of opposing rails, each of said rails being sized and shaped to receive a sliding roller. the sets of opposing rails are spaced so as to form a relative angle of 120 'to each other from the step of preparing the sliding rollers, the sliding rollers having a first portion having a set of parallel grooves on the first surface and a second portion which is designed so that engage with the first surface of the first portion of the sliding rollers, further from the step of preparing the state, this state having at least three legs equipped with grooves on the rotating trigo 37 ff IM. -W v In the vertical platform, the uprights have positioning surfaces that are designed to receive one of the corresponding first side block portions in a fixed manner, further from the step of drawing the fine wire into a state and into the grooves in the surface of the first portion of the sliding rollers. sliding rollers by placing a second portion of the sliding rollers in engagement with the first surfaces of the first sliding roller parts and separating the wires adjacent to the sliding rollers, further from the step of securing the sliding rollers to the opposite rail sets on the frame so as to form a wire matrix of wire filaments the pulleys are fixed to the frame so that the wires that are fixed to the frame intersect at an angle of approximately ISO, the wires form an equilateral triangle of the higher structures and the next step of welding the wires together to form a wire a grid having a flat construction. A method of manufacturing a grid wire material according to claim 6, characterized in that it additionally comprises the step of folding the wire grid so as to form a wire grid having a corrugated structure and / or a structure arranged in folds. A method of manufacturing a grid wire material according to claim 7, characterized in that it additionally consists of a wire grid that is cooked to one side of the step where the first portion has a flat structure, a crushed grid that is corrugated or has a folded structure. A method of manufacturing a grid wire material according to claim 8, characterized in that it additionally consists of the step of being a second portion of a wire grid that is cooked on the other side of a corrugated or folded wire grid having a flat structure of a grated grid having the structure, the second side having the folded structure, lies on the opposite side with respect to the first side of the wire grid having the folded structure. 10. A method of manufacturing a grid wire material, comprising the step of preparing a first retaining frame, the first retaining frame having a set of grooves for receiving a first group of fine wires, further from the step of preparing the second retaining frame, the second retaining frame having a set grooves for inserting a second group of fine wires further from the step of arranging the wires in the grooves of the second retaining frame and securing the group of wires in position, further from arranging the wire segments in the groove of the first retaining frame further from moving the first retaining frame and the second retaining frame together that the wire groups in the second cushion frame are aligned at a relative angle of 80 'relative to the wire segments in the first cushion frame, further from welding the wire groups in the second cushion frame, with the wire segments in the first cushion frame, manually inserting the wire segments into the first retainer frame and welding the wire segments with a plurality of wires in the second retainer frame to form a welded wire substructure, further from the step of arranging the welded wire substructure in the second retainer frame, the substructure having a plurality of wires being held a second frame retainer and wire segments that are held in the first frame retainer, further from the step of arranging the wire segments in the first frame retainer, further welding the partial wire structure with the wire segments positioned in the first frame retainer, further from the continuous wire insertion step holding frame and welding the wire segments with a partially welded wire structure to form a wire grid having a flat structure and further from the step of removing the wire grid from the first retainer and the second retaining frame. The method of manufacturing a grid wire material according to claim 10, further comprising the step of bending the wire grid to form a wire grid having a corrugated or folded structure. The method of manufacturing a grid wire material according to claim 11, further comprising the step of welding a first section of a wire mesh with a flat structure to one side of a wire mesh with a corrugated or folded structure. 13. The method of manufacturing a grid wire material of claim 18, further comprising the step of welding a second section of the wire grid having a flat structure to the other side of the wire grid with a corrugated or folded structure, the other side of the wire grid with / '. É mv corrugated structure It is located on the opposite side with respect to the side of the first wire mesh with the corrugated structure. A grid wire material of several groups of parallel wires (1,8, 3), characterized in that the grid wire material has at least three groups of parallel wires, further in that the wires of the individual groups (1, 8, 3) between each other they form an angle of at least 10 and a maximum of 90 °, and further that the wires of the groups (1, 3, 5) are welded together at their intersections (14). A grid wire characterized by a material between wire segments according to claim 14, characterized in that the spacing (18) of each group (1, 8, 3) the wire segments (18) and the relative angles between the wire segments (13) and the individual groups of the group (1, 3, 5) of the wire segments (13) are selected such that in each case one wire segment (13) of each of the three groups (1, 3, 3) runs through each intersection (14). A grid wire material according to claim 14 or claim 15, characterized in that the grid material (10) is folded in a accordion-like manner. The grid wire material of claim 16, wherein the fold lines extend along parallel rows of intersections (14). The grid wire material of claim 17, n-th (4) characterized in that either (a) and the length of the folded sections, that the angle extending perpendicularly to the fold lines, are selected between the intersections lying in one such that the distance (14) of the lattice material (10) is in the plane of the folded grid; ) did not survive the distance between the intersections of the movable grid material (10). A grid wire material according to claim 17, characterized in that the distance between the intersections (14) lying in one plane of the folded grid is in the coefficient of small integers with respect to the distance between the intersections (14) of the flat folded grid. The grid wire material according to claim 16 or one of the claims mentioned before claim 16, characterized in that, in the case of a flat non-folded grid, the angle between in each case the two wires of each wire group (1, 3, 3) is 60, in that the fold lines extend along the wires belonging to the group (1, 3, 3) of parallel wires, and further that the fold angle (α) is approximately 51.3 ", so that the intersection distances (14) on the fold line are coincident with the distances of the adjacent deflection peaks relative to each other. 31. A grid wire material of fibers, the fibers (16) being arranged in parallel in groups, and the fibers (16) of the various groups form an angle of at least 10 ' and at most 90 ' fr / λ? 4) of a flat mesh material produced by removing the spaced areas of the mesh material. 83. The fiber mesh of claim 31, wherein the removed areas of the mesh material are approximately triangular in shape (50), preferably with rounded corner areas. 83. The filament grid of claim 83, wherein the triangles (50) are disposed in at least two groups, and the orientation of the triangles (50) within the group is in each case identical and is different between the two groups, in particular being then rotated 180 * relative to the other group's triangle (50). The filament grid according to any one of claims 31 to 33, characterized in that the at least one initial grid wire material (10) is made of sheet metal. 85. A method of making a grid wire material, wherein the three groups of parallel wires are placed one over the other or interwoven with each other, the wires of one group are at least 10 ' and at most 90 ' together at their intersections. 86. A method of making a wire mesh material according to claim 25, wherein: 4 / that the arrangement of the wires is carried out in such a way that each intersection is made up of three wires and in particular in each case one of each individual group of wires. 87. A method for producing a grid wire material according to claim 85 or claim 86, wherein the grid wire material is folded in a accordion-like manner. 28. A method of manufacturing a grid wire material according to claim 27, wherein a plurality of grid wire materials, which are either flat or folded, are stacked in multiple layers and are welded to each other at least one portion of their contact points. A method of manufacturing a wire mesh material according to claim 28, characterized in that the two folded grids are connected to each other, preferably by welding, with the fold alignment turned 90 'relative to each other. 30. A method of manufacturing a grid wire material as claimed in any one of claims 21 to 24, wherein the substantially arranged surface areas are removed from the mesh material. A method for producing a grid wire material according to claim 30, characterized in that the surface areas are removed from the net material by shearing. 32. The method of making a filament-V grid wire material according to claim 31, wherein the sheet regions are removed from the mesh material by etching agents. 33. A method of manufacturing a wire grid material according to claim 58, wherein the structure of the surface areas to be removed by etching is prepared by photolithographic technology. Method for producing a grid wire material according to any one of claims 30 to 33, characterized in that a metal sheet is used as the mesh material. A method of manufacturing a grid wire material according to one of claims 30 to 34, characterized in that the net material, after removal of the planar areas that leaves a regular grid or net structure, is folded along the resulting grid or network of parallel intersection lines, that extend along the connecting lines of adjacent intersections.