WO2015047390A1

WO2015047390A1 - Milanese wire mesh, apparatus and method for weaving a milanese mesh

Info

Publication number: WO2015047390A1
Application number: PCT/US2013/062610
Authority: WO
Original assignee: Bodhi Technology Ventures Llc
Priority date: 2013-09-30
Filing date: 2013-09-30
Publication date: 2015-04-02

Abstract

An apparatus (600) for weaving milanese mesh material having a plurality of materials woven into the mesh carpet may take the form of wire feed device which includes a plurality of mandrels (610, 620, 630, 640, 650) each of which handles a different material. The mandrels may be movable such that as a woven row of milanese mesh is finished a new mandrel may be positioned at the next row to supply a second material. Each of the plurality of mandrels may be located on a single drum (660) configured to position a mandrel at the start of a new row to feed a new material.

Description

MILANESE WIRE MESH, APPARATUS AND METHOD FOR

WEAVING A MILANESE MESH

Technical Field

[0001] This disclosure relates generally to a wire mesh, and more particularly to a milanese wire mesh having adjacent coils with different physical attributes, and methods and systems for manufacturing the same.

Background

[0002] Milanese mesh is a decorative mesh made from a single material of metallic spiral wire threaded together, as illustrated for example in FIG. 1 . The material is sometimes used to make necklaces and bracelets. Typically, a spool containing wire material is set into a machine. The machine runs the wire material into a mandrel apparatus that forms the wire material into a spiral. The spiral is then forced forward and cut off at a certain length. After this, the machine makes the next spiral. The machine threads this new spiral into the already existing cutoff spiral. Once threaded the machine cuts off the new spiral. This process is continually repeated until a mesh carpet is formed. The mesh carpet consists of many spirals which have been threaded into one other.

[0003] Once the mesh carpet is formed, it is cut into various shapes depending on the end product. Typically, the product is short pieces of mesh. The pieces of mesh may be manually bound into a long strip utilizing another spiral of equal strength to join the discrete pieces together. The edges may then be processed to remove sharp and uneven coil ends. In this form the mesh is unstable as the individual coils can be removed. As such, the material may be locked so that the individual coils movement is significantly limited and the mesh carpet is secure. The locking is accomplished by pressing the strip flat and deforming the shape of the round coils.

[0004] Once locked, the mesh may be further processed to provide flexibility. The mesh may pass through a machine with cylinders that gyrate up and down forcing the mesh strip to bend back and forth. This treatment makes the mesh flexible but also leaves visible lines in the mesh from contact with the internal cylinders of the machine. Other processing steps may be used to improve the overall aesthetics of the mesh. Folding clasp and end pieces may be added by stamping the ends. The mesh strips may also undergo a polishing. [0005] The typical manufacturing process for milanese mesh devices does not allow for mesh carpets that are created with a plurality of different coils each having different attributes.

Summary [0006] This application discloses systems and methods for forming milanese mesh having adjacent coils with different physical attributes. In various embodiments, a milanese mesh includes a first coil of a first material and an adjacent second coil of a second material. The first coil of the first material may be threaded into the second coil of the second material forming the adjacent coils. The second coil and the first coil may have different attributes. The attributes may include at least one of a material type and a coil geometry. The coil geometry may include a difference in a coil wire diameter, a coil cross-section, and/or a coil turn frequency. The second coil of a second material may have a larger diameter of coil wire than the coil wire in the first coil of the first material. The second coil of a second material may have a larger coil cross-section than the first coil of the first material. The second coil of a second material may have a smaller coil frequency than the first coil of the first material. The first material may be a ferromagnetic material and the second material may not be a ferromagnetic material. For example, the first material may be a ferromagnetic stainless steel and the second material may be gold. [0007] In various embodiments, an apparatus for forming a milanese mesh having adjacent coils with different physical attributes may include a first mandrel and a second mandrel each having an engaged position and a disengaged position. The first mandrel may have a first spring forming die in communication with a first spool via a first metallic wire. The second mandrel may have a second spring forming die in communication with a second spool via a second metallic wire. A first mechanical actuator may rotate the first mandrel when the first mandrel is in the engaged position. A second mechanical actuator may rotate the second mandrel when the second mandrel is in the engaged position. A mesh carpet bed may be in communication with the first mandrel when in the engaged position via the first metallic wire and the mesh carpet bed may be in communication with the second mandrel when in the engaged position via the second metallic wire. The apparatus may also include a mandrel drum upon which the first mandrel and the second mandrel are mounted.

[0008] The apparatus may also include a third mechanical actuator which rotates the mandrel drum. In one example, the mandrel drum may have an axis of rotation parallel to an axis of rotation of the first mandrel and the second mandrel. In another example, the mandrel drum may have an axis of rotation perpendicular to an axis of rotation of the first mandrel and the second mandrel. The mandrel drum may rotate the first mandrel and the second mandrel relative to the carpet bed causing the first mandrel and the second mandrel to change between respective engaged positions. The carpet bed may not be in communication with the first mandrel when in the disengaged position via the first wire. The carpet bed may not be in communication with the second mandrel when in the disengaged position via the second wire. [0009] In various embodiments, a method for forming a milanese mesh device having adjacent coils with different physical attributes may include feeding a first material from a first spool onto a first mandrel and feeding a second material from a second spool onto a second mandrel. The first material may be coiled onto the first mandrel forming a first coil. The second material may be coiled onto the second mandrel forming a second coil. The first coil may be directed from the first mandrel toward a mesh carpet. A first new row may be formed on the mesh carpet by threading the first coil into an existing row of material. The drum may be rotated causing the second mandrel to align in a position to be threaded into the first new row on the mesh carpet of material. A second new row may be formed on the mesh carpet by threading the second material from the second mandrel into the first new row of material. The drum may be rotated causing a mandrel different than the second mandrel to align in a position to be threaded into the most recently created row on the mesh carpet. A third new row may be formed on the mesh carpet by threading a different coil than the second coil into the second new row. In various embodiments, a plurality of new rows of the second coil may be formed by repeating the process of threading the second coil into an outermost row on the mesh carpet. The process may include forming the mesh carpet such that the second coil and the first coil may have different attributes including coil wire diameter, coil cross-section, coil turn frequency, or coil material. In various embodiments, the first coil may be formed from a ferromagnetic material and the second coil might not be formed from a ferromagnetic material.

Brief Description of the Drawings

[0010] FIG. 1 shows an example of a prior art strip of milanese mesh.

[0011] FIG. 2A is an isometric view of an example of a portion of milanese mesh formed of a plurality of materials.

[0012] FIG. 2B is a schematic representation of the intertwining pattern of coils of a milanese mesh formed of a plurality of materials.

[0013] FIG. 3A is an isometric view of an example of a portion of milanese mesh formed of a plurality of different diameter coils.

[0014] FIG. 3B is a schematic representation of the intertwining pattern of coils of a milanese mesh formed of a plurality of different diameter coils.

[0015] FIG. 4A is an isometric view of an example of a portion of milanese mesh having formed of a plurality of coils of different thicknesses.

[0016] FIG. 4B is a schematic representation of the intertwining pattern of coils of a milanese mesh formed of a plurality of coils of different thicknesses.

[0017] FIG. 5A is an isometric view of an example of a portion of milanese mesh formed of a plurality of coils having different lengths between turns. [0018] FIG. 5B is a schematic representation of the intertwining pattern of coils of a milanese mesh formed of a plurality of coils having different turn pitches.

[0019] FIG. 6 is a schematic drawing of an embodiment of an apparatus for forming milanese mesh having adjacent coils with different physical attributes.

[0020] FIG. 7 is a schematic drawing of another embodiment of an apparatus for forming milanese mesh having adjacent coils with different physical attributes.

[0021] FIG. 8 is a schematic drawing of a further embodiment of an apparatus for forming milanese mesh from both ends of the mesh.

[0022] FIG. 9 is a flow chart of an embodiment of a process for forming milanese mesh having adjacent coils with different physical attributes.

Detailed Description

[0023] Generally, embodiments disclosed herein may include apparatus and methods for forming a milanese wire mesh having adjacent coils with different physical attributes. The milanese mesh material may have a plurality of materials woven into a mesh carpet. One embodiment of an apparatus for making the milanese mesh may take the form of wire feed device which includes a plurality of coiling mechanisms with respective mandrels, each of which handles a different material. The mandrels may be movable such that, as a woven row of milanese mesh is finished, a new mandrel may be positioned at the next row to supply a second material. Each of the plurality of mandrels may be located on a single drum configured to position a mandrel at the start of a new row to feed a new material. In one embodiment, the drum of mandrels may be arranged similar to a gun revolver allowing the mandrels to be moved by the drum which can switch back and forth between different materials on the different mandrels (or between different mandrels forming different coil patterns) while weaving the mesh carpet. This will enable multiple materials to alternate in any pattern.

[0024] As illustrated in FIGs. 2A-B, 3A-B, 4A-B and 5A-B, a mesh carpet 200, 300, 400 and 500 respectively may be formed from a plurality of different coils. For example, coils 202- 216, as illustrated in FIGs. 2A and 2B, may be threaded together to form the mesh carpet 200. One or more of the coils in the mesh carpet 200 (and similarly mesh carpet 300, 400, and 500 illustrated in FIGs. 3-5) may have different attributes as compared to the other coils in the mesh. The coil attributes may include wire material, wire size, wire shape, coil diameter, coil pitch, coil shape, or any additional similar attributes known or developed.

[0025] In various embodiments, each of the coils 202-216 in the mesh carpet 200 may be formed from a variety of materials including metals, polymers, or composites. The variance of materials may occur in any pattern. For example, each coil 202-216 may be a different material. In another exemplary implementation, every other coil may be the same material (e.g., coils 204, 208, 212, and 216 may be a first material and coils 202, 206, 210, and 214 may be a second material.) A larger portion of the mesh carpet 200 may be a first material with a smaller portion being the second material. The opposite could be applied as well with a larger portion of the mesh carpet 200 being a second material with a smaller portion being the first material. The second material may be concentrated in a specific area with the first material making up the remaining area of the mesh carpet 200 (e.g., coils 208 and 210 may be the second material and coils 202-206 and 212-216 may be the first material).

[0026] As illustrated in FIGs. 2A and 2B, coil 202 and coil 204 may be adjacent. Coil 202 may be a different material than coil 204 or it may be a similar material with a different material attribute. For example, ferromagnetic and non-ferromagnetic (e.g. paramagnetic and diamagnetic) metals may be combined to form the mesh carpet 200. Examples of ferromagnetic materials that may be utilized may include iron, nickel cobalt, chromium, and manganese. Additionally, ferromagnetic materials may include ferromagnetic alloys such as ferromagnetic stainless steel (e.g., 400 series stainless steel). Any other ferromagnetic material may be utilized as well. Examples of non-ferromagnetic materials that may be utilized may include copper, silver, gold, and non-ferromagnetic stainless steel (e.g., 300 series stainless steel). Any other non-ferromagnetic material may be utilized as well. For example, the composition of the mesh carpet 200 may include gold and ferromagnetic stainless steel. Stainless steel material may be utilized for its corrosion resistance and magnetic characteristics. Gold may be utilized for its aesthetics, weight, or workability. In various embodiments, coil 202 may be gold and coil 204 may be ferromagnetic stainless steel. The gold coils and the stainless steel coils may occur in any pattern. In other embodiments, some of the coils may be conductive (e.g., copper, aluminum, or gold) while other interwoven coils may be an insulator (e.g., plastics and other polymers, carbon fibers, or natural fibers capable of being formed in and holding a coil shape). Therefore, in the context of this application, the terms "coil" and "wire" may include forms made of non- metallic materials.

[0027] As illustrated in FIGS. 3A and 3B, adjacent coil 302 and coil 304 may be dissimilar in coil diameter size. In various embodiments, each of the coils 302-316 in the mesh carpet 300 may be formed from a variety of different coil diameter sizes. The occurrence of the variety of different coil diameter sizes may occur in any pattern. For example, each coil 302- 316 may be a different coil diameter size. In another embodiment, every other coil may be the same diameter size (e.g., coils 304, 308, 312, and 316 may be a first coil diameter size and coils 302, 306, 310, and 314 may be a second coil diameter size.) In accordance with various embodiments, a larger portion of the mesh carpet 300 may be a first coil diameter size with a smaller portion being the second diameter size. For example, the first coil diameter size may be larger than the second coil diameter size. The opposite could be applied as well with a larger portion of the mesh carpet 300 being the smaller diameter size with a smaller portion being the larger diameter size. In various embodiments, the second coil diameter size may be concentrated in a specific area with the first diameter size making up the remaining area of the mesh carpet 300 (e.g., coils 308 and 310 may be the second diameter size and coils 302-306 and 312-316 may be the first diameter size). Any combination, pattern, or arrangement of various coil sizes may be utilized to form mesh carpet 300. [0028] As illustrated in FIGs. 4A and 4B, adjacent coil, 402 and 404 may be dissimilar in wire diameter size (e.g., wire guage). In various embodiments, each of the coils 402-416 in the mesh carpet 400 may be formed from a variety of different wire diameter sizes. The occurrence of the variety of different wire diameter sizes may occur in any pattern. For example, each coil 402-416 may be a different wire diameter size. Every other coil may be the same wire diameter size (e.g., coils 404, 408, 412, and 416 may be a first wire diameter size and coils 402, 406, 410, and 414 may be a second wire diameter size.) In accordance with various embodiments, a larger portion of the mesh carpet 400 may be formed of coils having a first wire diameter size with a smaller portion being formed of coils having the second wire diameter size. For example, the first wire diameter size may be larger than the second wire diameter size. The opposite could be applied as well with a larger portion of the mesh carpet 400 being the smaller wire diameter size with a smaller portion being the larger wire diameter size. In various embodiments, the second wire diameter size may be concentrated in a specific area with the first wire diameter size making up the remaining area of the mesh carpet 400 (e.g., coils 408 and 410 may be the second wire diameter size and coils 402-406 and 412-416 may be the first wire diameter size). Any combination, pattern, or arrangement of various wire sizes may be utilized to form mesh carpet 400.

[0029] As illustrated in FIGs. 5A and 5B, adjacent coils 502 and 504 may be dissimilar in coil pitch. In various embodiments, each of the coils 502-516 in the mesh carpet 500 may be formed from a variety of different coil pitches. The variety of different coil pitches may occur in any pattern. For example, each coil 502-516 may be a different coil pitch. Every other coil may be the same coil pitch (e.g., coils 504, 508, 512, and 516 may be a first coil pitch and coils 502, 506, 510, and 514 may be a second coil pitch.) In accordance with various embodiments, a larger portion of the mesh carpet 500 may be formed of coils with the first coil pitch with a smaller portion being formed of coils with the second coil pitch. For example, the first coil pitch may be smaller than the second coil pitch. It may be noted that the coil pitches may be harmonic. The first coil pitch may have half the frequency of turns compared to the second coil pitch. As illustrated, coil 502 has three turns and coil 504 has six turns. However, any harmonic coil pitch ratio may be applicable between the first coil pitch and the second coil pitch. In another example, a larger portion of the mesh carpet 400 may have the larger coil pitch with only a small portion being the smaller coil pitch. In various

embodiments, the second coil pitch may be concentrated in a specific area with the first coil pitch making up the remaining area of the mesh carpet 500 (e.g., coils 508 and 510 may be the second coil pitch and coils 502-506 and 512-516 may be the first coil pitch). Any combination, pattern, or arrangement of various coil pitch may be utilized to form mesh carpet 500. [0030] In accordance with various embodiments, the mesh carpet may include any combination of the various attributes. While the examples and embodiments discussed herein show only a limited number of coils, it may be noted that a mesh carpet can by any number of coils and as such it is understood that the examples and embodiments discussed herein is merely illustrative of a portion of a mesh carpet. [0031] In accordance with various embodiments, as shown in FIG. 6 and FIG. 7, a mesh forming system having a plurality of mandrels may be utilized to form the mesh carpet having adjacent coils with different attributes. As shown in FIG. 6, the mesh forming system 600 may include a first mandrel 610 mounted on a drum 660. The first mandrel 610 may include a coil forming die 614. The coil forming die 614 may be utilized to form the coil 604 around the first mandrel 610. The first mandrel 610 may have an engaged position and a disengaged position. As illustrated in FIG. 6 the first mandrel 610 may be engaged such that the first mandrel 610 directs coil 604 onto mesh carpet 602. The first mandrel 610 may be in communication with a first spool 612 whereby the first spool 612 feeds a first wire 613 to the first mandrel 610. [0032] The mesh forming system 600 may also include a second mandrel 620. The second mandrel 620 may include a coil forming die 624. The coil forming die 624 may be utilized to form the coil around the second mandrel 620. The second mandrel 620 may have an engaged position and a disengaged position. As illustrated in FIG. 6 the first mandrel 610 is disengaged such that the first mandrel 610 does not direct a coil onto carpet 602. The second mandrel 620 may be in communication with a second spool 622 and receive a second wire 623 from the second spool 622. In accordance with various embodiments, the mesh forming system 600 may include any number of additional mandrels such as three total mandrels, four total mandrels, five total mandrels, six total mandrels or so on. For example, as illustrated in FIG. 6, the mesh forming system 600 may include five mandrels. Each mandrel (610, 620, 630, 640, or 650) may have a coil forming die (i.,e., 614, 624, 634, 644, or 654, respectively). Each mandrel (610, 620, 630, 640, or 650) may be in communication with a spool (6120, 622, 632, 642, or 652) to receive a respective wire (613, 623, 633, 643, or 653). Each mandrel (610, 620, 630, 640, or 650) may also be placed in an engaged position and a number of disengaged positions based upon the position of the drum 660. FIG. 6 shows first mandrel 610 in the engaged position.

[0033] In accordance with various embodiments, each of the mandrels (610, 620, 630, 640, or 650) may be configured to coil wires with different attributes. For example, the first mandrel 610 may be configured to coil a first wire 613, which may be a non-ferromagnetic wire like gold. In this example, the first spool 612 may be spooled with the first wire 613. The first spool 612 may feed the first wire 613 to the first mandrel 610 when the first mandrel 610 is in the engaged position. The second mandrel 620 may be configured to coil a second wire 623 that is, for example, ferromagnetic. In this example, a second spool 622 may be spooled with the second wire 623 of ferromagnetic material. The second spool 622 may feed the second wire 623 to the second mandrel 620 when the second mandrel 620 is in the engaged position. It may be noted that any spool and mandrel pair may be configured to spool and coil, respectively, any material or any wire with any attribute. Any additional mandrel and spool (e.g., 630, 640, 650 and 632, 642, 652, respectively) may be likewise configured to handle any material with any attribute. Each of the spools and mandrels may be configured to handle different materials or attributes of wire. [0034] In accordance with various embodiments, as shown in FIG. 6, the mandrels may be mounted onto a drum 660 which rotates about an axis 672. The mandrels may be mounted proximal to the outer circumference of the drum 660. This may be true regardless of the number of mandrels in the embodiment. Each mandrel may rotate independently of any other mandrel. The drum 660 and each mandrel may also rotate independently of each other. In various embodiments, the axis 672 of rotation of the drum 660 may be parallel to an axis of rotation of each of the mandrels mounted thereon, such as the first mandrel 620. Each mandrel's axis of rotation may also be parallel to additional mandrels mounted on the drum 660. This arrangement also allows one or more mandrels to point toward the mesh carpet 602. The drum 660 merely needs to rotate to align each of the mandrels mounted thereon with the mesh carpet 602. The drum 660 may rotate to a plurality of different positions providing an engaged position for each of the mandrels (e.g., 610, 620, 630, 640, or 650). The engaged position for each mandrel allows the mandrel to feed a new coil into the next row of mesh carpet. Once the row is complete the mesh system 600 may have a cutting device (not shown) to cut the coil and allow the current mandrel to start another row or rotate the drum to engage a new mandrel for a new row with a different attribute. [0035] The mesh forming system 600 may include a carpet bed 606. The carpet bed 606 may be configured to support the formed mesh carpet 602. As shown in FIG. 6, the carpet bed 606 may receive a coil 604 of the first wire 613 from the first mandrel 610 when the first mandrel 620 is in the engaged position. The carpet bed 606 may receive another coil formed of the second wire 623 from the second mandrel 620 when the second mandrel 620 is in the engaged position. The carpet bed 606 may similarly be in communication with any additional mandrels in the system (e.g., 630, 640, or 650) to receive coils formed of their respective wires (e.g., 633, 643, or 653) in their respective engaged positions. The carpet bed 606 may not be in communication with the first mandrel 610 when the first mandrel 610 is in its disengaged position. Similarly, the carpet bed 606 may not be in communication with the second mandrel 620 when the second mandrel 620 is in its disengaged position. The carpet bed 606 may not be in communication with any additional mandrels in the system (e.g., 630, 640, or 650) when the mandrels are in their respective disengaged positions.

[0036] The mesh forming system 600 may also include a coil locator 680. The coil locator 680 may be configured to aid in aligning the coil 604 being threaded into the mesh carpet 602 with the new row on mesh carpet 602 which receives the new coil.

[0037] In accordance with another embodiment of the mesh system, as shown in FIG. 7, the mesh forming system 700 may include also include a plurality of mandrels. Similar to other embodiments, a first mandrel 720 may include a coil forming die 724. The coil forming die 724 may be utilized to form the coil around the first mandrel 720. The first mandrel 720 may have an engaged position and a disengaged position. As illustrated in FIG. 7 the first mandrel 720 may be engaged such that the first mandrel 720 directs coil 704 onto mesh carpet 702. The first mandrel 720 may be in communication with a first spool 722. The first spool 722 may feed the first wire 723 to the first mandrel 720 when the first mandrel 720 is in the engaged position.

[0038] The mesh forming system 700 may also include a second mandrel 730. The second mandrel 730 may include a coil forming die 734. The coil forming die 734 may be utilized to form the coil around the second mandrel 730. The second mandrel 730 may have an engaged position and a disengaged position. As illustrated in FIG. 7 the second mandrel 730 is disengaged such that the second mandrel 730 does not direct a coil onto mesh carpet 702. The second mandrel 730 may be in communication with a second spool 732. The second spool 732 may feed a second wire 733 to the second mandrel 730 when the second mandrel 730 is in the engaged position. In accordance with various embodiments, the mesh forming system 700 may include any number of additional mandrels such as three total mandrels, four total mandrels, five total mandrels, six total mandrels or so on. For example, as illustrated in FIG. 7, the mesh forming system 700 may include four mandrels. Each mandrel (720, 730, 740, or 750) may have a coil forming die (e.g., 724, 734, 744, or 754 respectively). Each mandrel (720, 730, 740, or 750) may be in communication with a spool (722, 732, 742, or 752) to receive a respective wire (723, 733, 743, or 753). Each mandrel (720, 730, 740, or 750) may also be placed in an engaged position and a number of disengaged positions based upon the position of the drum 760. FIG. 7 shows first mandrel 720 in the engaged position by directing a coil 704 towards mesh carpet 702.

[0039] In accordance with various embodiments, each of the mandrels (720, 730, 740, or 750) may be configured to coil wires with different attributes. For example, mandrel 730 may be configured to coil wire 733 which may have a larger diameter wire than other wires. In this example, spool 732 may be spooled with the large diameter wire 733 and feed it to the second mandrel 730. Mandrel 720 may be configured to coil a wire that is, for example, a small diameter wire (e.g., smaller in diameter than the example wire 733). In this example, spool 722 may be spooled with the small diameter wire 723. The first spool 722 may feed the first wire 723 to the first mandrel 720. It may be noted that any spool and mandrel pair may be configured to spool and coil, respectively, any material or any wire with any one or more of the specific attributes discussed herein. Any additional mandrel and spool (e.g., 740, 750 and 742, 752 respectively) may be likewise configured to handle any material with one or more of the attributes discussed herein. Each of the spools and mandrels may be configured to handle different materials or attributes of wire as compared to the other spools and mandrels in the same mesh system.

[0040] In accordance with various embodiments, as shown if FIG. 7, the mandrels may be mounted onto a drum 760 which rotates about an axis 762. The mandrels (720, 730, 740, 750) may be mounted proximal to the outer circumference of the drum 760. This may be true regardless of the number of mandrels in the embodiment. Each mandrel may rotate independently of any additional mandrel. The drum 760 and each mandrel may rotate independently of each other.

[0041] As distinguished from FIG. 6, FIG. 7 shows an embodiment of the mandrel drum 760 wherein the drum 760 may have an axis of rotation offset from the axis of rotation of the mandrels mounted thereon, such as the first mandrel 720. The offset may be ninety degrees. This offset allows the drum 760 to rotate causing the one or more mandrels mounted thereon to point outwardly from the axis of rotation. Additionally, each mandrel's axis of rotation may also be offset from the other mandrel's axes of rotation. For example this offset may be ninety degrees as illustrated. But it may be noted that any offset from zero to three- hundred-sixty degrees may be used. This offset also allows one or more mandrels to point away from one another. This also allows the end of each mandrel to be maintained the same distance from the mesh carpet 702. With the same distance maintained between mandrels and the mesh carpet 702, the drum 760 merely needs to rotate to engage a new mandrel with the mesh carpet 702. The drum 770 may rotate to a plurality of different positions providing an engaged position for each of the mandrels (e.g., 720, 730, 740, or 750). The engaged position for each mandrel allows the mandrel to feed a new coil into the next row of mesh carpet. Once the row is complete the mesh system 700 may cut the coil with a cutting device (not shown) and allow the current mandrel to start another row or rotate the drum to engage a new mandrel for a new row with a different attribute. [0042] The mesh forming system 700 may include a carpet bed 706. The carpet bed 706 may be configured to support the formed mesh carpet 702. The carpet bed 706 may receive the first wire 723 the first mandrel 720 when the first mandrel 720 is in the engaged position. The carpet bed 706 may be in communication with the second mandrel 730 via the second wire 733 in response to the second mandrel 730 being in the second mandrel's engaged position. The carpet bed 706 may similarly be in communication with any additional mandrels in the system (e.g., 730, 740, or 750) via their respective wires (e.g., 733, 743, or 753) in their respective engaged positions. The carpet bed 706 may not be in communication with the first mandrel when the first mandrel 720 is in its disengaged position. Similarly, the carpet bed 706 may not be in communication with the second mandrel 730 when the second mandrel 730 is in its disengaged position. The carpet bed 706 may not be in communication with any additional mandrels in the system (e.g. 730, 740, or 750) when the mandrels are in their respective disengaged positions. The mesh forming system 700 may also include a coil locator 780. The coil locator 780 may be configured to aid in aligning the coil 704 being threaded into the mesh carpet 702 with the new row on mesh carpet 702 which receives the new coil.

[0043] As distinguished from FIG. 6 and FIG. 7, FIG. 8 shows an embodiment, of the mesh system 800 wherein the plurality of mandrels are not located on a drum but instead located on opposite sides of the mesh carpet 802. For example, a first mandrel 820 may be located on a first side of a carpet bed 806. First mandrel 820 may receive a first material 823 from a first spool 822. First mandrel 820 may coil first material 823 into coil 804 on die 824 and deliver the first material to the mesh carpet. A second mandrel 830 may be located on a second side of a carpet bed 806. The second mandrel 830 may receive a second material 833 from a second spool 832. The second mandrel 830 may coil the second material 833 into coil 805 on die 834 and deliver the second material 833 to the mesh carpet. This also allows each mandrel to apply a new coil to the mesh carpet from different sides. In one embodiment, the mandrels may be located not just on opposite sides such that the mandrels may feed coils into opposite sides of the carpet, the mandrels may be located on opposite ends of the carpet (arrow A proximal to one end of the mesh carpet and arrow B proximal to the other end of the mesh carpet.) In this configuration, as shown in FIG. 8, the first mandrel 820 may apply coils on a first end of the mesh carpet and the second mandrel 830 may apply coils on a second end of the mesh carpet. In another embodiment, the mandrels (820 and 830) may both be located on the same end of the carpet (e.g. both mandrel 820 and 830 may be located on the end proximal to arrow A or both mandrel 820 and 830 may be located on the end proximal to arrow B.) Similar to the other embodiments, each mandrel 820 and 830 may be configured to coil and apply wires with different attributes from one another. As such, a mesh carpet may be formed with wires having different attributes. For example, spool 822 may contain a wire with a first attribute and spool 832 may contain a wire with a second attribute. While shown in FIG. 8 with two mandrels, in accordance with various embodiments, the mesh forming system 800 may include any number of additional mandrels such as 3 total mandrels, or 4 total mandrels. [0044] The mesh forming system 800 may include a carpet bed 806. The carpet bed 806 may be configured to support the formed mesh carpet 802. The carpet bed 806 may be in communication with the first mandrel 820 via the first wire 823 in response to the first mandrel 820 being in the first mandrel's engaged position. The carpet bed 806 may be in communication with the second mandrel 830 via the second wire 833 in response to the second mandrel 830 being in the second mandrel's engaged position. The carpet bed 806 may not be in communication with the first mandrel via the first wire in the first mandrel's unengaged position. Similarly, the carpet bed 806 may not be in communication with the second mandrel via the second wire in the second mandrel's un-engaged position. As the mesh carpet grows, the relationship of the new row location will change especially as new rows are being added to both ends of the mesh carpet 802. To align the rows in this embodiment, the carpet bed 806 may be configured to translate back and forth along arrows A and B in order to align the new row of the mesh carpet with the mandrel applying the new coil. In another embodiment, the carpet bed 806 may be able to rotate as illustrated by arrow C. By rotating, the carpet bed 806 may be operable to align new rows with the different material

[0045] The mesh forming system 800 may also include a coil locator 880. The coil locator 880 and 890 may be configured to aid in aligning the new coils 804 and 805 with the new row on mesh carpet 802 which receives the new coil.

[0046] In accordance with various embodiments, as shown in FIG. 9, a method for forming a mesh carpet having adjacent coils with different physical attributes may include a variety of operations for utilizing a plurality of mandrels having wires with different attributes. Operation 900 may start the process. In operation 905, a first material may be fed from a first spool onto a first mandrel. In operation 910, the first material may be coiled onto the first mandrel forming a first coil. In operation 915, the first coil may be directed off of the first mandrel toward a mesh carpet. In operation 920, a first new row may be formed on the mesh carpet by threading the first coil into an existing row of material. In operation 925, the drum may be rotated causing the second mandrel to align in a position to be threaded into the first new row on the mesh carpet. In operation 930, a second material may be fed from a second spool onto a second mandrel. In operation 935, the second material may be coiled onto the second mandrel forming a second coil. In operation 940, a second new row may be formed on the mesh carpet by threading the second material from the second mandrel into the first new row of material. This process may be continued and varied until the mesh carpet is fully formed. In operation 945 the process ends. It may be noted that these operations may be performed in any order as understood by a person of ordinary skill in the art. For example, operation 930 or 935 may be performed prior to operation 925 such that the material is fed to or coiled on the mandrel before the second mandrel is aligned in a position to thread the second material into the mesh carpet.

[0047] In accordance with various embodiments, a plurality of new rows of the second coil may be formed by repeating the operation of threading the second coil into an outer most row on the mesh carpet. Additionally, the drum may be rotated again causing a mandrel different than the second mandrel (and in various embodiments the first mandrel) to align in a position to be threaded into the most recently created row on the mesh carpet. Thus third new may be added to the mesh carpet forming a new row by threading a different coil into the previous new row. The method may include forming the mesh carpet such that the second coil and the first coil may have different attributes including coil wire diameter, coil cross-section, coil turn frequency, or coil material. For example, the first coil may be formed from a ferromagnetic material and the second coil might not be formed from a ferromagnetic material. It may be noted that the mesh carpet may be formed from any combination of attributes in any pattern. [0048] As used throughout this document in each of the embodiments, aspects, examples, lists and various descriptions of the subject matter contained herein, the word "or" is intended to be interpreted in its inclusive form (e.g. and/or) not in its exclusive form (e.g. only one of) unless explicitly modified to indicate only one item in a list is intended (e.g. only one of A, B, or C). For example, the phrase A, B, or C is intended to include any combination of the elements. The phrase can mean only A. The phrase can mean only B. The phrase can mean only C. The phrase can mean A and B. The phrase can mean A and C. The phrase can mean B and C. The phrase can mean A and B and C. This concept extends to any length of list (e.g. 1 , 2, 3... or n) used herein.

[0049] Although the foregoing discussion has presented specific embodiments, the foregoing merely illustrates the principles of the invention. Persons skilled in the art will recognize that changes may be made in form and detail without departing from the spirit and scope of the disclosure as various modifications and alterations to the described embodiments will be apparent to those skilled in the art, in view of the teachings herein. For example, the processing steps may be performed in another order, or in different combinations. It will thus be appreciated that those having skill in the art will be able to devise numerous systems, arrangements and methods which, although not explicitly shown or described herein, embody the principles of the disclosure and are thus within the spirit and scope of the present invention. From the above description and drawings, it will be understood by those of ordinary skill in the art that the particular embodiments shown and described are for purposes of illustration only, and references to details of particular embodiments are not intended to limit the scope of the present invention, as defined by the appended claims.

Claims

CLAIMS We claim:

1 . An apparatus comprising

a first mandrel having an engaged position and a disengaged position, with the first mandrel having a first coil-forming die in communication with a first spool providing a first wire;

a second mandrel having an engaged position and a disengaged position, with the second mandrel having a second coil-forming die in communication with a second spool providing a second wire;

a carpet bed in communication with the first mandrel in its engaged position via the first wire and in communication with the second mandrel in its engaged position via the second wire.

2. The apparatus of claim 1 , wherein the carpet bed is not in communication with the first mandrel via the first wire when the first mandrel is in the disengaged position.

3. The apparatus of claim 1 , wherein the carpet bed is not in communication with the second mandrel via the second wire when the second mandrel is in the disengaged position.

4. The apparatus of claim 1 further comprising:

a mandrel drum upon which the first mandrel and the second mandrel are mounted, wherein the mandrel drum is configured to rotate and place the first mandrel in the engaged position and to further rotate and place the first mandrel in the disengaged position and the second mandrel in the engaged position.

5. The apparatus of claim 4, wherein the mandrel drum rotates independently of coil-forming rotations of the first mandrel or the second mandrel.

6. The apparatus of claim 5, wherein the mandrel drum has an axis of rotation parallel to an axis of rotation of each of the first mandrel and the second mandrel.

7. The apparatus of claim 1 , wherein the mandrel drum has an axis of rotation offset from an axis of coil-forming rotations of each of the first mandrel and the second mandrel.

8. The apparatus of claim 4, wherein the mandrel drum rotates the first mandrel and the second mandrel relative to the carpet bed causing the first mandrel and the second mandrel to change between the engaged position of the first mandrel and the engaged position of the second mandrel.

9. A method for weaving a milanese mesh comprising:

feeding a first material from a first spool onto a first mandrel;

feeding a second material from a second spool onto a second mandrel;

coiling the first material onto the first mandrel and forming a first coil;

coiling the second material onto the second mandrel and forming a second coil; directing the first coil off of the first mandrel toward a mesh carpet;

forming a first new row on the mesh carpet by intertwining the first coil into an existing coil row of the mesh carpet;

rotating a drum having the first mandrel and the second mandrel mounted thereon and thereby causing the first mandrel to un-align with an edge of the mesh carpet and causing second mandrel to align with the edge of the mesh carpet.

10. The method of claim 9 further comprising forming a second new row on the mesh carpet by threading the second coil from the second mandrel into the first new row of material.

1 1 . The method of claim 10 further comprising rotating the drum and thereby causing a mandrel different than the second mandrel mounted on the drum to align in a position to be threaded into the mesh carpet.

12. The method of claim 1 1 further comprising forming a third new row on the mesh carpet by threading a different coil than the second coil into the second new row.

13. The method of claim 10 further comprising forming a plurality of new rows of the second coil by repeating the process of threading the second coil into an outer most row of the mesh carpet.

14. The method of claim 8, wherein the second coil and the first coil have different attributes including one or more of the following: coil diameter, coil cross-section diameter, coil pitch, or coil material.

15. The method of claim 8, wherein the first coil is made of a ferromagnetic material and the second coil is not made of a ferromagnetic material.

16. A milanese mesh comprising

a first coil having a first attribute; and

a second coil having a second attribute that is different than the first attribute; wherein the first coil is intertwined with the second coil.

17. The milanese mesh of claim 16, wherein a difference between the first attribute and the second attribute includes one of more of the following: a difference in a coil material, a difference in a coil diameter, a difference in a coil wire cross-section diameter, or a difference in coil pitch.

18. The milanese mesh of claim 16, wherein the second coil has a larger cross- section diameter of coil wire than a coil wire of the first coil.

19. The milanese mesh of claim 16, wherein the first coil is made of a ferromagnetic material and the second coil is not made of a ferromagnetic material.

20. The milanese mesh of claim 19, wherein the first coil is made of a ferromagnetic stainless steel and the second coil is made of gold.