WO2005085507A1

WO2005085507A1 - Mesh and method of manufacture

Info

Publication number: WO2005085507A1
Application number: PCT/US2005/006413
Authority: WO
Inventors: John Frederick Porter
Original assignee: Saint-Gobain Technical Fabrics Canada, Ltd.; Saint-Gobain Technical Fabrics America, Inc.
Priority date: 2004-03-01
Filing date: 2005-02-28
Publication date: 2005-09-15

Abstract

A coated mesh having interlaced flexible yarns, and a coating on the yarns, wherein the coating consists of, a first polymeric resinous material combined with a monomer and/or oligomer of a second polymeric resinous material in a low viscosity dispersion for spreading as a thin uncured coating, and wherein stiffness of the coating when cured is adjusted by adjusting the quantity of the monomer and/or oligomer in the dispersion.

Description

MESH AND METHOD OF MANUFACTURE FIELD OF THE INVENTION [0001] The present invention relates to a mesh of interlaced yarns adapted for use as an insect screen, and, alternatively, for use as a reinforcing mesh in a reinforced tape or sheet. Further, the present invention relates to a mesh having a low profile thickness and a method of making the mesh.

BACKGROUND OF THE INVENTION [0002] U.S. Patent 6,716,774 discloses a polymer coated web or mesh having yarns of fiberglass, that are interlaced to form an open mesh for use as an insect screen, followed by the web or mesh being coated with a polymer coating of polyvinyl chloride, PNC, polymer. Then the PNC is heat-set. Coating the mesh with a polymeric material requires the polymer to be dispersed in a solvent with a low viscosity. The low viscosity promoted spreading of the polymeric material, while avoiding a tendency of the polymeric material to accumulate in the openings in the mesh. However, the resin is widely dispersed in the low viscosity coating. Consequently, the coating has a relatively low stiffness after heat-setting. [0003] It would be desirable to retain the flexibility of the coated mesh for such uses, as a retractable insect screen, while producing a stiffer polymer coating that is stiffened by an appropriate amount to resist wrinkling and buckling. However, prior to the invention, a conventional manner of producing a stiffer polymer was to increase the concentration of polymeric resin material in its solvent, which increased the viscosity of the polymeric coating. However, when spreading a higher viscosity polymeric material as a coating on a mesh, the higher viscosity polymeric material tends to build-up in the mesh openings, which defeats an open mesh feature. Further, a higher viscosity polymeric material tends to buildup as a thick coating, which produces a thick mesh that is incapable of compact storage when the thick mesh is retracted inside a cassette housing or wound onto a reel. [0004] An alternative attempt to increase polymer stiffness by heat-setting the polymer with the application of heat, either with an extended temperature range or for an extended period of time, causes polymer discoloration, heightened odor and a reduction in useful life due to heat aging.

[0005] Prior to the invention, a relatively stiff insect screen was made of aluminum mesh. However, aluminum, and any other metal, is susceptible to wrinkling and buckling. In addition, aluminum mesh is subject to mechanical and thermal creep. Further, aluminum mesh is a thermal conductor and thermal energy radiator, which contributes to heat transfer through a door or window. A desired polymer coated fiberglass or polymeric mesh would resist wrinkling and buckling, and would retard heat transfer.

SUMMARY OF THE INVENTION [0006] The present invention relates to a coated mesh having interlaced flexible yarns, and a coating on the yarns, wherein the coating consists of, a first polymeric resinous material combined with a monomer and/or oligomer of a second polymeric resinous material in a low viscosity dispersion for spreading as a thin uncured coating, and wherein stiffness of the coating when cured is adjusted by adjusting the quantity of monomer and/or oligomer in the dispersion. Advantageously, the low viscosity promotes spreading to form a thin coating on the yarns. [0007] Further, the present invention relates to a method of making a mesh of low profile thickness for compact rolling up on itself into a compact roll, for example, to fit inside a cassette housing without jamming.

[0008] Further, the invention relates to a method making a coated mesh, comprising: combining a first polymeric resinous material with a monomer and/or oligomer of a second polymeric resinous material in a low viscosity dispersion; adjusting the relative quantity of the monomer and/or oligomer in the dispersion to adjust the stiffness of a coating formed by the dispersion; applying the dispersion as a low viscosity coating on flexible yarns; heating and cooling the coating to a thermoplastic state; interlacing the coated yarns to form a coated mesh; melting the coating; and solidifying the coating to form a coating having an adjusted stiffness. [0009] Further, the present invention relates to a method of coating yarns for a mesh, comprising: combining a first polymeric resinous material with a monomer and/or oligomer of a second polymeric resinous material in a low viscosity dispersion for spreading as a low viscosity coating on the mesh; adjusting the quantity of the monomer and/or oligomer in the dispersion to adjust the stiffness of the coating when cured to form a solidified coating; and curing the coating to form a solidified coating. Advantageously, the solidified coating has a flexible polymerized polymeric material and a polymerized, monomer and/or oligomer that adjusts the stiffness of the solidified coating. [0010] Embodiments of the present invention will become apparent by way of example from the following detailed description taken in conjunction with the accompanying drawings. SUMMARY OF THE DRAWINGS

[0011] Figure 1 is a fragmentary enlarged view of a portion of a coated mesh.

[0012] Figure 2 is a schematic view of apparatus for making a coated yarn.

[0013] Figure 3 is a schematic view of apparatus for making a coated mesh. DETAILED DESCRIPTION

[0014] With reference to Fig. 1, the present invention relates to a mesh 10 of flexible interlaced yarns 12 and a coating 14 on the yarns. The coating 14 comprises a first polymeric resinous material combined with a monomer and/or oligomer of a second polymeric resinous material in a dispersion having a low viscosity for ease in spreading, wherein the monomer and/or oligomer adjusts the stiffness of the coating 14 when the coating 14 is cured to form a solidified coating 14. Preferably, the amount of reactive monomer and/or oligomer is about 5-50 parts per hundred parts of the first polymeric resinous material. The coating 14 is cured, for example, by the application of heat, including other forms of energy, for example, irradiation, as appropriate for curing the polymeric material and either, the monomer and/or oligomer, or both, to form a solidified coating 14. [0015] The terminology, "yarns," as used herein, refers to strands, threads or filaments, and combinations thereof, which are twisted or untwisted. Preferably, the yarns 12 comprise untwisted fiberglass. Preferably, the yarns 12 comprise fiberglass, a high strength flexible material. Further, the yarn material includes but is not limited to, fiberglass, polyesters, polyimides, polyolefins, and other high strength, flexible materials.

[0016] The terminology, "interlaced yarns," refers to yarns 12 that are interlaced with one another by being woven, knitted, braided or intertwined in some way or another, randomly or according to a pattern, in a textile-like manner to form an open mesh 10. Preferably, the interlaced yarns 12 are interlaced by a simple weave to form an open mesh 10. Further, the open mesh 10 is preferably flattened to become thin, or having a low profile thickness. [0017] According to a preferred embodiment, the polymeric material of the coating 14 comprises a polymeric resin compounded with a plasticizer. The terminology, "polymeric resin," refers to a thermoplastic material, preferably in powder form, prior to being compounded with the plasticizer. According to a preferred embodiment of the invention, the polymeric resin comprises polyvinyl chloride, PVC.

[0018] The terminology, "plasticizer," refers to a substance of moderate to high molecular weight, that is compounded with a polymeric resin to impart viscosity and flexibility to a polymer formed by curing the polymeric resin. According to a preferred embodiment of the invention, the plasticizer comprises any of the plasticizers known to be chemically compatible with PVC to impart viscosity to a dispersion and to impart softness and flexibility to the PVC when cured to a solid form.

[0019] According to a preferred embodiment of the invention, the resin and plasticizer and a low amount of solvent, for example, mineral spirits or Varsol, together comprise a dispersion, for example, a plastisol dispersion. A monomer and or oligomer combine with the resin, the plasticizer and the low amount of solvent in the dispersion to form a low viscosity dispersion in both a liquid plastisol stage and a melted or molten stage. The low viscosity attribute promotes spreading in a thin dispersion coating 14, while avoiding a build up of excessive thickness. [0020] A "monomer and/or oligomer," refers to a group of molecules and/or polymers having a number of molecules, which molecules are reactive, either in the presence of a catalyst, or without a catalyst, for alloying, and/or interknit mingling, with the polymeric resin and the plasticizer to form a permanently solidified coating 14, preferably a coating in a thermoset state or a crosslinked state, or at least solidified to an extent approaching a thermoset state or a crosslinked state. Desirably, the preferred coating 14 on the yarns 12 is formed to a solidified thermoplastic state, first, by melting the preferred coating 14 in a first heating chamber, followed by cooling. Subsequently, the preferred coating 14 is formed to a permanent solidified state by melting the preferred coating 14 in a second heating chamber, and continuing to apply heat to the melted preferred coating 14 for a prolonged time period corresponding to a prolonged curing period required to cure the preferred coating 14 to a permanent solidified state. The permanent solidified state at least approaches a solidified thermoset state, or approaches a crosslinked molecular state, wherein either state prevents melting after solidification of the coating 14. [0021] The preferred monomer and/or oligomer composition is selected for remaining in a melted state during a desired prolonged curing period under heat. The preferred composition is selected for having a slow curing rate or an inefficient curing rate that provides the desired prolonged curing period under heat. The prolonged curing rate is either inherent in the composition without a catalyst, or the curing rate is lowered or rendered less efficient, either by a low efficiency catalyst, that the preferred monomer and or oligomer composition requires the application of heat for a lengthy curing period before approaching or attaining a permanent solidified state. [0022] Suitable monomers and oligomers include polyfunctional acrylates, methacrylates, epoxies, allyl cyanurates, urethanes, unsaturated polyesters and cyanoacrylates. Trifunctional acrylic monomers (e.g., trimethyl propane trimethacrylate) are particularly preferred. Suitable catalysts include peroxides and azo initiators for the unsaturated monomers, and Lewis bases for the epoxy type. Suitable levels of reactive monomers or oligomers are in the range of 5-50 pph (parts per hundred resin) range, with suitable catalyst levels in the range of about 0-3 pph. The catalyst can be activated by, e.g., heat or radiation.

[0023] A preferred polyfunctional monomer and/or oligomer consists of, a polyfunctional acrylic monomer, including but not limited to, triallyl cyanurates, an epoxy with hardener, a high molecular weight polystyrene, and combinations thereof. [0024] A preferred embodiment of the present invention consists of, a polyfunctional monomer and/or oligomer including but not limited to, a polyfunctional acrylate, a polyfunctional methacrylate, or a trifunctional acrylic monomer, and combinations thereof. [0025] According to a preferred embodiment, the monomer and/or oligomer is selected from the group consisting of polyfunctional acrylates, methacrylates, epoxies, allyl cyanurates, urethanes, unsaturated polyesters, unsaturated cyanoacrylates, and combinations thereof.

[0026] A "polyfunctional" monomer and or oligomer, adapted for use in the coating 14, refers to a monomer and or oligomer having multiple covalent bond sites available for cross linking. The crosslinking rate should be sufficiently prolonged, either in the presence of a catalyst, or without a catalyst, such that crosslinking is either incomplete, or delayed, during heating in a first heating chamber, for example, the first heating chamber 26, Fig. 2, and crosslinking is completed during prolonged heating in a second heating chamber, for example, the second heating chamber 36, Fig. 3.

[0027] The monomer and/or oligomer in the form of a second polymeric resinous material is added to the dispersion having a first polymeric resinous material, the plasticizer and the low amount of solvent, which lowers dispersion viscosity. Although a low viscosity could be obtained by increasing the solvent concentration, a preferred embodiment of the invention contains a relatively low amount of solvent, and relies upon the monomer and/or oligomer to lower the dispersion viscosity. A low amount of solvent in the dispersion is desirable, because an undesired, high solvent concentration produces solvent outgases to the environment, and further, produces solvent blisters in the coating 14. Further, solvent residues produce an odor that is present in a solidified form of the dispersion coating 14. [0028] In the dispersion, the dispersion viscosity decreases with increases in concentration of the plasticizer. Adding the monomer and/or oligomer to the dispersion further decreases the dispersion viscosity, which augments spreading of the low viscosity dispersion as a thin coating 14. The added monomer and/or oligomer may allow for a reduction of some of the plasticizer in the dispersion. The plasticizer imparts flexibility to the PVC coating 14 on the yarns 12, as disclosed by U.S. 6,716,774. Thus, a reduction in the plasticizer will adjust the PVC coating 14 with lessened flexibility. However, reducing the plasticizer in the dispersion would undesirably increase the dispersion viscosity. Thus, adding the monomer and/or oligomer desirably reduces the dispersion viscosity to promote spreading as a thin coating 14. The concentration of the polymeric resin remains sufficiently high in the dispersion, and remains in significant high concentration when spread as a thin coating 14. Advantageously, the low viscosity allows the coating 14 to be spread thinly, while avoiding a thick build-up on each of the yarns 12. [0029] A preferred first embodiment of a low viscosity dispersion comprises, a plastisol dispersion consisting of, a 2 to 1 ratio of a first polymeric resinous material, PVC, to a PVC plasticizer that imparts viscosity, softness and flexibility to the PVC, combined with mineral spirits or Varsol solvent comprising a small quantity as described herein. A monomer and/or oligomer, having a composition as described herein, is added as a second polymeric resinous material, together with a suitable catalyst, as described herein. The quantity of the second polymeric resinous material is adjusted to impart viscosity to the dispersion, and further, to impart a solidified form of the dispersion an adjusted stiffness, when spread as a thin coating on the strands 12, followed by curing to form a permanent solidified coating. [0030] A second preferred embodiment of a low viscosity dispersion, comprises an additive in the first preferred embodiment of the low viscosity dispersion. The additive comprises, a plasticizer, Texanol Benzyl Phthalate, TBP, known for having a low plasticizer efficiency. The plasticizer of low efficiency imparts less reduction in tensile strength of un- plasticized PVC, than does a high efficiency plasticizer. According to the invention, at least a portion of the plasticizer comprises TBP as an additive in the first preferred embodiment of the low viscosity dispersion, which advantageously imparts an adjusted stiffness to the PVC coating 14, when combined desirably with the preferred plasticizer that imparts desired softness and flexibility to the PVC coating 14. A preferred 2 to 1 ratio of PVC polymeric resinous material to the plasticizer is desired. Thereby, TBP substitutes for some of the preferred first plasticizer in the dispersion. [0031] An unappreciated property of the TBP additive, is that it decreases the dispersion viscosity in both the liquid plastisol stage and the molten stage, without causing a reduction in stiffness of the PVC coating 14, as would the typical or ordinary plasticizers. Further, the TBP additive in the dispersion may substitute for some of the second polymeric resinous material, the monomer and/or oligomer, in the dispersion, without increasing the dispersion viscosity. A relative reduction in the amount of monomer and/or oligomer may extend the melted state duration of the coating 14 during the curing period, and/or may allow a reduction of the heat needed for curing the coating 14 during the curing period. [0032] With reference to Fig. 2, the dispersion is processed, by coating each of the yarns 12 with a preferred thin coating 14 of a preferred low viscosity dispersion. For example, each of the yarns 12 is guided through a corresponding orifice 16 at an apex of a hollow cone 18, and through another orifice 20 in a reservoir 22 containing the low viscosity dispersion 24. Each yarn 12 exits through a corresponding reservoir orifice 20, together with a preferred thin coating 14 of the low viscosity dispersion.

[0033] Following application of the thin coating 14, each of the yarns 12 is conveyed through a corresponding first heating chamber 26 that briefly heats each of the coated yarns 12 to melt the preferred coating 14 to a melted thermoplastic state. For example, a preferred coated yarn 12 as described herein has a preferred diameter of about 0.011 inches (.028 mm.) is heated at about 400° F. (173.1° C.) for two seconds, followed by ambient cooling. When each continuously conveyed, coated yam 12 leaves the first heating chamber 26, the preferred coating 14 is cooled to solidify the preferred coating 14 in a solidified thermoplastic state. Each of the coated yams 12 is wound onto a corresponding storage spool 28. The preferred coating 14 is in a solidified thermoplastic state that allows melting and/or re-melting of the preferred coating 14. The preferred coating 14 has sufficient toughness to withstand a process of interlacing the coated yams 12 to form an open mesh 10. The coated yams 12 comprise a product made by the method described herein. One of the intended uses for the coated yams 12 is for making a mesh, for example, the mesh 10. [0034] Fig. 3 discloses that the coated yams 12 are continuously supplied to an industry standard loom 30 that interlaces the coated yams 12 to form a simple weave, open mesh 10, shown in Fig. 1, having lengthwise warp yams 12 and transverse weft yams 12. As the mesh 10 is formed continuously by the loom 30, the mesh 10 is continuously conveyed from the loom 30 by passage over a feed roller 32 that applies lengthwise tension on the warp yams 12 of the mesh 10. The weft yams 12 are placed in lateral tension for example, by idler rollers 34 that spread the mesh 10 laterally.

[0035] The conveyed mesh 10 passes through a lengthy, second heating chamber 36. The second heating chamber 36 heats the mesh 10 while the mesh 10 is under tension. The thermoplastic coating 14 on the yams 12 of the mesh 10 is melted by the heat. When the melted coating 14 solidifies, it forms thermoplastic bonds between the coated, warp and weft yams 12 where they cross over one another in the mesh 10, as shown in Fig. 1.

[0036] The coated yams 12 have substantially circular cross sections when interlaced by the loom 30 to form the mesh 10. Further, while the mesh 10 is being heated, the tension applied to the coated yams 12 tends to press the coated yams 12 against one another, where they cross over one another in the mesh 10. [0037] The warp and weft yams 12 press against one another at the cross-over intersections, and, thereby, become flattened, as shown in Fig. 1. The flattened cross-over intersections are sufficiently close together along each of the interlaced yams 12, that they urge the yams 12 to acquire apparent flattened cross sections along short distances thereof extending between the cross-over intersections. Thus, each of the coated yams 12 in the mesh 10 has a flattened thickness along its entire length, which produces a desirably thin mesh 10. Each of the preferred yams 12 of about 0.011 inch diameter cross over one another when interlaced in the mesh 10. The preferred mesh 10 is about 0.022 inches thick at each of the crossover portions. A preferred thin mesh 10 has flattened yams 12. Further, the preferred thin mesh 10 is flattened to about 0.013 inches at the cross over portions. [0038] Thereafter, the preferred coating 14 is cured to form a solidified coating 14. The preferred coating 14 is cured by the application of heat or by irradiation, as appropriate for polymerization and otherwise congealing of both the polymer material and the monomer and or oligomer. Further, the applied heat or irradiation drives off any solvent volatiles that may be present in the preferred coating 14.

[0039] With reference to Fig. 3, the mesh 10 continues to be heated while under tension as it is being conveyed and pulled through the second heating chamber 36 by the feed roller 32. The second heating chamber 36 applies heat to the mesh 10 throughout a curing period of time that is sufficiently prolonged to flatten the coated mesh prior to, the preferred coating 14 at least approaching, if not attaining, a solidified thermoset state that can not be melted, or approaching if not attaining, a crosslinked molecular state. The desired monomer and or oligomer has a lengthy curing period before attaining a permanent solidified state, including but not limited to, a thermoset state and a crosslinked molecular state. The monomer and or oligomer is selected to polymerize with the application of heat over a prolonged period of curing time.

[0040] According to another embodiment of the invention, an even thinner mesh 10 can be produced by providing a pair of nip rollers 38, in Fig. 3, that compress the mesh 10 therebetween. The nip rollers 38 further flatten the mesh yams 12 that have been previously flattened by warp tension applied by the feed roller 32 and weft tension applied by the idler roller 34. A preferred thin mesh 10 is about 0.011 inch to about 0.012 inch thickness at each of the cross over intersections of the flattened warp and weft yams 12. [0041] The nip rollers 38 are in close proximity to the downstream end of the second heating chamber 36, such that they flatten the coated yams 12 before the coated yams 12 cool significantly after leaving the second heating chamber 36. The mesh 10 must be at an elevated temperature when compressed between the nip rollers 38. A heated mesh 10 apparently undergoes plastic flow when compressed between the nip rollers 38. The compression strain in response to being compressed is apparently relieved by the plastic flow, which permanently sets the flattened shapes of the coated yams 12. If the mesh 10 has cooled somewhat before being compressed between the nip rollers 38, the compression strain in the flattened mesh 10 becomes stress relieved by undesired, resilient expansion of the mesh 10 yams 12 over the passage of time, for example, overnight. [0042] According to a preferred embodiment of the present invention, during the curing period, the preferred monomer and/or oligomer combines with the polymeric resin host polymeric material to form an intermingled network of the polymerized polymeric material and the polymerized, monomer and or oligomer in the cured coating 14. [0043] Further, when the preferred polymeric material has a chemical affinity for alloying with the monomer and/or oligomer, during the curing period, the polymeric material combines with the monomer and/or oligomer by alloy formation in the cured coating 14. For example, when the polymeric material comprises PVC resin, the PVC resin has an affinity for alloying with the preferred embodiments of the monomer and oligomer substances, as disclosed herein.

[0044] The solidified coating 14 bonds to the yams 12, and particularly bonds to the yams 12 where the interlaced yams 12 form cross-over intersections with one another. The stiffness of the coating 14 can be adjusted by adding an appropriate amount of monomer and/or oligomer to the dispersion. Further, by adding the reactive monomer and/or oligomer to the dispersion, an amount of plasticizer can be reduced without causing a significant increase in viscosity of the dispersion, and without significant concentration reduction of the polymeric material in the dispersion. The relative amount of plasticizer and the relative amount of reactive monomer and/or oligomer are adjusted to produce a dispersion of appropriate viscosity, and to produce a cured coating 14 that is flexible, but having an appropriate amount of stiffness.

[0045] The polymer coated, flexible mesh 10 according to the invention is stiffly flexible compared to a limber, flexible mesh 10 that is more pliant, and thereby, susceptible to wrinkling and buckling. Further, according to the invention, the stiffness of the coated mesh 10 is appropriately increased, due to the adjusted stiffness of the cured coating 14, to resist wrinkling and buckling, while sufficient flexibility of the mesh 10 is retained for roll- up retraction onto a reel or retraction inside a cassette housing. The polymer coated, flexible mesh 10 according to the invention is sufficiently flexible for roll-up onto a reel or inside a cassette housing, and further has a stiffness appropriate to resist wrinkling or buckling. For example, a preferred stiffness is between standard, flexible fiberglass insect screening and more rigid, aluminum screening. [0046] According to another preferred embodiment of the present invention, a mesh having a flexible coating, as disclosed by U.S. 6,716,774, can be converted to a mesh 10 having an adjusted stiffness, according to an embodiment of the invention. Coatings are often applied in two or more coats. The first coat comprises, a standard, flexible coating of flexible polymer, for example, PVC. Thereby, a flexible mesh is manufactured according to U.S. 6,716,774. The flexible mesh 10 can be converted to a stiffly flexible mesh. A second coating 14 is applied over the first coating 14. The second coating 14 comprises a thin coating 14 according to the present invention, thereby to manufacture a mesh 10 with an appropriate amount of stiffness. {0047] While the mesh 10 according to the present invention preferably substitutes as a replacement for aluminum insect screen, and is particularly suitable for retractable screen doors and windows, it has other uses. For example, a coated mesh 10 according to the present invention can be used for strength reinforcement of tapes and sheets. The mesh 10 can have an appropriate stiffness that adds resistance to wrinkling and buckling of the tapes and sheets, as well as, added strength reinforcement. Typical tapes and sheets consist of materials disclosed by U.S. Patents 3,214,289 and 4,587,997. Mesh reinforcement is usually referred to as, scrim, woven glass fiber scrim and open-weave mesh, as disclosed in U.S. Patents 4,552,004 and 4,525,970 and 4,578,915. [0048] The disclosure of each patent, patent application, and publication cited herein is hereby incorporated herein by reference in its entirety.

[0049] While this invention has been disclosed with reference to specific embodiments, it is apparent that other embodiments and variations of this invention can be devised by others skilled in the art without departing from the true spirit and scope of the invention. The appended claims include all such embodiments and equivalent variations.

Claims

1. A coated mesh, comprising: interlaced flexible yams, and a coating on the yams, wherein the coating consists of, a first polymeric resinous material combined with a monomer and/or oligomer of a second polymeric resinous material in a low viscosity dispersion for spreading as a thin uncured coating, and wherein stiffness of the coating when cured is adjusted by adjusting the quantity of monomer and/or oligomer in the dispersion.

2. The mesh of claim 1, wherein the polymeric material comprises a polymer resin and a plasticizer.

The mesh of claim 2, wherein the polymer is polyvinyl chloride.

4. The mesh of claim 1 wherein the coating when cured consists of, a polymerized polymeric material and a polymerized, monomer and/or oligomer, in either an alloy thereof, or an intermingled network thereof.

5. The mesh of claim 1 , wherein the coating when cured consists of, a polymerized polymeric material and a polymerized, monomer and/or oligomer in both an intermingled network thereof, and an alloy thereof.

6. The mesh of claim 1, wherein each of the yams has a flattened thickness profile.

7. The mesh of claim 1 , wherein at least a portion of the plasticizer comprises Texanol Benzyl Phthalate.

8. The mesh of claim 1, wherein the ratio of the first resinous material to the plasticizer is about 2 to 1.

9. The mesh according to claim 1, wherein the monomer and or oligomer is about 5-50 parts per hundred parts of the first polymeric resinous material.

10. The mesh according to claim 1 wherein, the monomer and or oligomer consists of, a polyfunctional acrylic monomer, including but not limited to, triallyl cyanurates, an epoxy with hardener, a high molecular weight polystyrene, and combinations thereof.

11. The mesh according to claim 1 wherein, the monomer and or oligomer is selected from the group consisting of polyfunctional acrylates, methacrylates, epoxies, allyl cyanurates, urethanes, unsaturated polyesters, unsaturated cyanoacrylates, and combinations thereof.

12. The mesh according to claim 1 wherein, the monomer and or oligomer consists of, a polyfunctional monomer and/or oligomer including but not limited to, a polyfunctional acrylate, a polyfunctional methacrylate, or a trifunctional acrylic monomer, and combinations thereof.

13. A mesh comprising: flexible interlaced yams; and a coating on the yams, the coating comprising, a first polymeric resinous material combined with a monomer and/or oligomer of a second polymeric resinous material that adds stiffness to the coating when cured; and the polymeric material and the reactive monomer and/or oligomer having a low viscosity while being applied as a coating on the yams, wherein the low viscosity promotes spreading to form a thin coating.

14. A method making a coated mesh, comprising: combining a first polymeric resinous material with a monomer and/or oligomer of a second polymeric resinous material in a low viscosity dispersion; adjusting the relative quantity of the monomer and/or oligomer in the dispersion to adjust the stiffness of a coating formed by the dispersion; applying the dispersion as a low viscosity coating on flexible yams; heating and cooling the coating to a thermoplastic state; interlacing the coated yams to form a coated mesh; melting the coating; and solidifying the coating to form a coating having an adjusted stiffness.

15. The method of claim 14, further comprising: forming an alloy of the first polymeric resinous material and the monomer and or oligomer in the solidified coating.

16. The method of claim 14, further comprising: forming an intermingled network of the first polymeric resinous material and the monomer and/or oligomer in the solidified coating.

17. The method according to claim 14, further comprising: flattening the coated yams while melting the coating.

18. The method according to claim 14, further comprising: flattening the coated yams while melting the coating, by applying tension on the mesh.

19. The method according to claim 14, further comprising: flattening the coated yams while melting the coating, by applying tension on the mesh; and by applying compression on the mesh.

20. A method of making coated yams for use in a mesh, comprising: combining a first polymeric resinous material with a monomer and/or oligomer of a second polymeric resinous material in a low viscosity dispersion for spreading as a low viscosity coating on the yams; adjusting the relative quantity of the monomer and/or oligomer in the dispersion to adjust the stiffness of a solidified coating formed by curing the low viscosity coating; and cooling the low viscosity coating to form a solidified thermoplastic coating.

21. The method of claim 20, further comprising: forming an alloy of the first polymeric resinous material and the monomer and/or oligomer in the solidified coating.

22. The method of claim 20, further comprising: forming an intermingled network of the first polymeric resinous material and the monomer and/or oligomer in the solidified coating.