WO2017091365A1

WO2017091365A1 - Unitary expanded metal mesh having linear down-roll strands

Info

Publication number: WO2017091365A1
Application number: PCT/US2016/061492
Authority: WO
Inventors: Larry S. Hebert; Michael D. Swan; Scott A. Boyd
Original assignee: 3M Innovative Properties Company
Priority date: 2015-11-24
Filing date: 2016-11-11
Publication date: 2017-06-01
Also published as: JP2019503865A; CA3006038A1; EP3380259A1; US20200254502A1

Abstract

A unitary expanded metal mesh is provided having a down-roll direction, the mesh comprising: a) linear strands that are substantially parallel to the down-roll direction; and b) cross strands which meet the linear strands at nodes. Composites including the unitary expanded metal mesh of the present disclosure and a polymeric matrix are also provided. The unitary expanded metal mesh and composites may be provided as roll goods having, in some embodiments, uninterrupted linear down-roll metal strands for unlimited length. Methods of making the unitary expanded metal mesh of the present disclosure are provided.

Description

UNITARY EXPANDED METAL MESH HAVING LINEAR DOWN-ROLL

STRANDS Field of the Disclosure

This disclosure relates to a unitary expanded metal mesh having linear down- roll metal strands and thus enhanced tensile strength in the down-roll direction; having, in some embodiments, uninterrupted linear down-roll metal strands for unlimited length.

Background of the Disclosure

Presently, expanded metal mesh is produced from rolls of metal sheet by a repeating process of simultaneously cutting and bending the sheet near its leading edge with a tool positioned perpendicular to the down -roll direction of the metal sheet, i.e., parallel to the cross-sheet direction. The tool includes numerous projections of a triangular or arcurate shape, extending orthogonal to the sheet. The sheet is borne on a supporting surface including at its front edge a stationary cutting edge that works in tandem with the tool to cut the sheet. As the tool is brought down on the sheet near its leading edge, a slit is cut in the sheet by each projection. In addition to cutting a slit, each projection bends downward a thin strand of metal bordering each slit, such that the strand bulges in a direction orthogonal to the plane of the metal sheet. The tool leaves a node of metal uncut between each strand. The sheet is advanced and the process repeated, however the tool is shifted between two alternate positions with each stroke. The nodes of the first position are centered in the slits of the second position and vice-versa. In some cases, it is the tool that remains stationary and the position of the sheet is shifted between two alternate positions with each stroke.

With reference to FIG. 3, the resulting mesh 310 of expanded metal includes voids 320 having the general shape of a parallelogram, i.e., diamond-shaped (or potentially square), with a major axis 322 perpendicular to the down-roll direction of the sheet 390 and a minor axis 324 parallel to the down-roll direction of the sheet 390. The voids are bounded by diagonal metal strands 330, which are oriented diagonal to the down-roll direction of the sheet 390. The diagonal metal strands 330 meet at nodes 340

Summary of the Disclosure

Briefly, the present disclosure provides a unitary expanded metal mesh having a down-roll direction, the mesh comprising: a) linear strands that are substantially parallel to the down-roll direction; and b) cross strands which meet the linear strands at nodes; wherein the unitary expanded metal mesh is greater than 3.00 meters in length measured in the down-roll direction. In some embodiments, the linear strands are parallel to the down-roll direction to a tolerance of +/- 10 degrees of angle over the length of the mesh; in some the linear strands are parallel to the down-roll direction to a net tolerance of +/- 10 degrees of angle summed over the entire length of the mesh. In some embodiments, the unitary expanded metal mesh is greater than 8.00 meters in length measured in the down-roll direction and in some greater than 900.00 meters in length measured in the down-roll direction. In some embodiments, the unitary expanded metal mesh comprises copper, tin, gold, silver, nickel, zinc, iron, aluminum or alloys thereof. In some embodiments, the unitary expanded metal mesh has a thickness of less than 1.800 mm and greater than 0.010 mm. In some embodiments, the unitary expanded metal mesh has an average distance between nodes measured along linear strands of less than 4.000 cm and greater than 0.030 cm. In some embodiments, the unitary expanded metal mesh is a unitary stretched-expanded metal mesh. Additional embodiments of the unitary expanded metal mesh of the present disclosure are described below under "Selected Embodiments."

In another aspect, the present disclosure provides a composite material comprising: c) the unitary expanded metal mesh according to the present disclosure; and d) a polymeric matrix. In various embodiments, the polymeric matrix may be an uncured curable resin, a partially cured curable resin, a cured curable resin, a thermoset resin, or an epoxy resin. In some embodiments, the composite material may additionally comprising one or both of: e) a woven fiber scrim; or f) a non-woven fiber scrim. In some embodiments, the composite material may be a sheet material having a thickness of less than 6.00 mm and greater than 0.020 mm. Additional embodiments of the composite material of the present disclosure are described below under "Selected Embodiments."

In another aspect, the present disclosure provides a method of making a unitary expanded metal mesh according to the present disclosure comprising the steps of: : g) providing a metal sheet having a down-roll direction; h) simultaneously cutting the metal sheet near its leading edge and bending strands of the metal of the sheet by use of a tool positioned at a diagonal to the down-roll direction of the metal sheet, wherein the cutting comprises cutting a row of slits separated by gaps in the sheet, and wherein the bending comprises bending downward a thin strand of metal of the sheet bordering each slit such that the strand bulges in a direction orthogonal to the plane of the metal sheet; i) advancing the metal sheet in the down-roll direction; and j) repeating step h), such that the gaps in adjacent rows of slits fall in a line substantially parallel to the down-roll direction of the metal sheet. In some embodiments, the tool comprises a plurality of projections extending in a direction orthogonal to the sheet. In some embodiments, the projections are of a triangular or arcurate shape extending in a direction orthogonal to the sheet. In some embodiments, the row of slits is a row of parallel slits. In some embodiments, the row of slits is a row of co-linear slits. In some embodiments, the tool is shifted, relative to the lateral position of the sheet, between two alternate positions with each repetition of step h). In other embodiments, the tool is not shifted, relative to the lateral position of the sheet, between repetitions of step h). In some embodiments, the step of providing a metal sheet comprises providing a roll of metal sheet having a down-roll direction parallel to the long side of the rolled metal sheet; and in such cases the method is typically a continuous process by roll. Additional embodiments of the methods of the present disclosure are described below under "Selected Embodiments."

In another aspect, the present disclosure provides a method of making a unitary expanded metal mesh according to the present disclosure comprising the steps of: p) providing a metal sheet having a down-roll direction; q) slitting the sheet to form a slit metal sheet bearing a plurality of rows of slits separated by gaps, wherein the rows of slits are oriented at a diagonal to the down-roll direction of the sheet and wherein the gaps in adjacent rows of slits fall in a line substantially parallel to the down-roll direction of the metal sheet; and r) stretching the slit metal sheet in a direction not parallel to the down-roll direction of the metal sheet to form the unitary expanded metal mesh. In some embodiments, the row of slits is a row of parallel slits. In some embodiments, the row of slits is a row of co-linear slits. In some embodiments, the step of providing a metal sheet comprises providing a roll of metal sheet having a down-roll direction parallel to the long side of the rolled metal sheet; and in such cases the method is typically a continuous process by roll. Additional embodiments of the methods of the present disclosure are described below under "Selected Embodiments."

In another aspect, the present disclosure provides a unitary metal mesh having a down-roll direction, the mesh comprising: a) linear strands that are substantially parallel to the down-roll direction; and b) cross strands which meet the linear strands at nodes; wherein the unitary metal mesh is greater than 3.00 meters in length measured in the down-roll direction and in some embodiments greater than 900.00 meters in length measured in the down-roll direction. Additional embodiments of the unitary metal mesh of the present disclosure are described below under "Selected Embodiments."

What has not been described in the art, and is provided by the present disclosure, is a unitary metal mesh having linear down-roll metal strands - in some embodiments uninterrupted linear down-roll metal strands for unlimited length - and thus enhanced tensile strength in the down-roll direction. Thus, in some embodiments, the unitary metal mesh provided in the present disclosure has great utility in automated applications that use long continuous roll materials, such as automated fiber placement and automated tape lay up.

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

As used in this specification and the appended claims, the term "unitary" excludes items formed by joining two or more articles. For example, a woven metal mesh such as a window screen is not unitary since it is formed by joining multiple sets of wires, nor would any mesh derived therefrom be unitary.

As used in this specification and the appended claims, the term "expanded mesh" excludes a mesh formed by perforating a sheet or otherwise cutting a sheet to form holes by removing material. In some embodiments, the "expanded mesh" of the present disclosure is limited to a "stretch-expanded mesh," meaning a mesh or portion thereof formed by cutting and stretching a sheet or portion thereof so as to increase its area and form a mesh.

As used in this specification and the appended claims, the term "continuous process by roll" means a process that is operated continuously from the loading of roll good raw materials until at least one of the roll good raw materials is expended.

As used in this specification and the appended claims, the singular forms "a", "an", and "the" encompass embodiments having plural referents, unless the content clearly dictates otherwise.

As used in this specification and the appended claims, the term "or" is generally employed in its sense including "and/or" unless the content clearly dictates otherwise.

As used herein, "have", "having", "include", "including", "comprise", "comprising" or the like are used in their open ended sense, and generally mean "including, but not limited to." It will be understood that the terms "consisting of and "consisting essentially of are subsumed in the term "comprising," and the like.

Brief Description of the Drawing

FIG. 1 is an expanded metal mesh according to certain embodiments of the present disclosure, wherein 190 indicates the down-roll direction of the sheet.

FIG. 2 is a slit metal foil useful in certain embodiments of Method II of the present disclosure, wherein 290 indicates the down-roll direction of the sheet.

FIG. 3 is a prior art expanded metal mesh, wherein 390 indicates the down-roll direction of the sheet.

Detailed Description

The present disclosure provides a unitary expanded metal mesh having linear down-roll metal strands. As a result, the mesh has enhanced tensile strength in the down-roll direction. In some embodiments the unitary expanded metal mesh includes uninterrupted linear down-roll metal strands for unlimited length. In many embodiments, the unitary expanded metal mesh is provided as a roll good or incorporated in a roll good, and in many such embodiments the length of uninterrupted linear down-roll metal strands in the mesh is limited only by roll length. As a result, the unitary expanded metal mesh of the present disclosure is particularly useful in applications that use long continuous roll materials, such as automated fiber placement and automated tape lay up, and can be supplied in rolls of 1000 meters length or more.

With reference to FIG. 1, one embodiment of the unitary expanded metal mesh 110 of the present disclosure includes voids 120 having the general shape of a parallelogram, i.e., diamond-shaped (or potentially square), with a major axis 122 diagonal to the down-roll direction of the sheet 190, i.e., neither parallel to nor perpendicular to the down-roll direction of the sheet 190; and a minor axis 124 diagonal to the down-roll direction of the sheet 190, i.e., neither parallel to nor perpendicular to the down-roll direction of the sheet 190. The voids are bounded by linear strands 135, which are oriented generally parallel to the down-roll direction of the sheet 190, and cross strands 130, which are oriented diagonal to or perpendicular to the down-roll direction of the sheet 190. The linear strands 135 and cross strands 130 meet at nodes 140. In some embodiments, linear strands 135 are uninterrupted down- roll strands of unlimited length, i.e., limited in length only by the roll length of the mesh.

The linear strands are substantially parallel to the down-roll direction. In this disclosure, "parallel to the down-roll direction" refers to orientation in the general plane of the sheet or mesh ("left and right"), and disregards out-of-plane variation ("up and down"). In some embodiments, the linear strands are parallel to the down-roll direction to a tolerance of +/- 10 degrees of angle over the mesh length; in some embodiments the tolerance is less. In some embodiments, the net variation from parallel of the linear strands is small over long runs, such that individual linear strands run for very long lengths within the mesh. In some embodiments, the net variation from parallel of the linear strands is cumulatively positive or negative, such that individual linear strands initiate at one edge of the mesh and terminate at the other edge over a given length of mesh, typically at least 3.00 meters, more typically at least 4.00 meters, more typically at least 6.00 meters, more typically at least 8.00 meters, and more typically at least 12.00 meters. Thus, in some embodiments, the linear strands are parallel to the down-roll direction to a net tolerance of +/- 10 degrees of angle, being the departure from parallel summed over the entire mesh length; in some embodiments the tolerance is less. In some embodiments, the unitary expanded metal mesh of the present disclosure is provided as a roll good having a length of greater than 3.00 meters, in some embodiments greater than 4.00 meters, in some embodiments greater than 6.00 meters, in some embodiments greater than 8.00 meters, in some embodiments greater than 12.00 meters, in some embodiments greater than 22.00 meters, in some embodiments greater than 52.00 meters, in some embodiments greater than 520.00 meters, in some embodiments greater than 900.00 meters, and in some embodiments greater than 1400.00 meters. In some embodiments the expanded metal mesh is unitary throughout the length of the roll, without any splices or seams.

In some embodiments, the unitary expanded metal mesh of the present disclosure is incorporated in a composite material, which is in some embodiments a sheet material. In some embodiments, the composite includes the unitary expanded metal mesh of the present disclosure and a polymeric matrix. Suitable polymeric matrices may include thermoplastic resins, uncured curable resins, partially cured or B- staged curable resins, cured curable resins, thermoset resins, and in some embodiments epoxy resins. Additional components of the composite material may include woven fiber scrims, non-woven fiber scrims, filler particles, pigments, and the like.

The authors have found that tapes of a composite of epoxy resin matrix and unitary expanded metal mesh of the present disclosure are capable of bearing a peak load more than 2.5 times greater than a tapes of a composite of the same epoxy resin matrix and a prior art expanded metal mesh, such as depicted in FIG. 3.

The unitary expanded metal mesh of the present disclosure may be made by any suitable method, including methods I, lb and II described herein. Method of Making I

In one embodiment, the unitary expanded metal mesh of the present disclosure is produced from rolls of metal sheet by a repeating process of simultaneously cutting and bending the sheet near its leading edge with a tool positioned at a diagonal to the down-roll direction of the metal sheet. The tool includes numerous projections, typically of a triangular or arcurate shape, extending orthogonal to the sheet. The projections are typically parallel to each other and more typically co-linear. The sheet is borne on a supporting surface including at its front edge a stationary cutting edge that works in tandem with the tool to cut the sheet, and is therefore also positioned at a diagonal to the down-roll direction of the metal sheet, in parallel with the tool. As the tool is brought down on the sheet near its leading edge, a slit is cut in the sheet by each projection. In addition to cutting a slit, each projection bends downward a thin strand of metal bordering each slit, such that the strand bulges in a direction orthogonal to the plane of the metal sheet. The tool leaves a node of metal uncut between each strand. The sheet is advanced and the process repeated. Nodes of adjacent rows must fall in a line substantially parallel to the down-roll direction of the metal sheet.

In some embodiments, the tool is shifted between two alternate positions with each stroke. The nodes of the first position are centered in the slits of the second position and vice-versa. In some cases, it is the tool that remains stationary and the position of the sheet is shifted between two alternate positions with each stroke. In either case, the tool is shifted, relative to the lateral position of the sheet (i.e., cross- sheet), between two alternate positions with each stroke.

Method of Making lb

In some embodiments of method I (designated method lb), neither the tool nor the sheet is shifted between alternate positions. Instead, they remain in a single position relative to each other, excepting the down-roll movement of the sheet. The tool is not shifted, relative to the lateral position of the sheet (i.e., cross-sheet), between strokes. The positioning is chosen such that, with repeating strokes, the nodes of adjacent rows fall in a line substantially parallel to the down-roll direction of the metal sheet. In such embodiments, the production mechanism is simplified, capital expense can be reduced and line speed increased by eliminating the need to shift the tool (or sheet) between alternate positions.

Method of Making II

In one embodiment, with reference to FIG. 2, the unitary expanded metal mesh of the present disclosure is produced from rolls of metal sheet 210 by first slitting the sheet with rows of slits 250 oriented at a diagonal to the down-roll direction of the sheet 290. Slits 250 of each row are typically parallel to each other and more typically co-linear. In each row of slits, nodes 240 of the unitary expanded metal mesh are gaps between slits. The nodes 240 of adjacent rows of slits fall in a line substantially parallel to the down-roll direction of the metal sheet. Slitting can be accomplished by any suitable method, including without limitation rotary cutting, laser cutting, and the like.

In a second step of method II, the slit sheet is stretched in a direction perpendicular to the down-roll direction of the sheet 290 or diagonal to the down-roll direction of the sheet 290 but not parallel to slits 250, such that the slits open to form voids having the general shape of a parallelogram and the width of the sheet is increased. The stretching step may be accomplished by any suitable method.

Method of Making III

In one embodiment, a unitary metal mesh (i.e., not expanded), similar in some respects to the unitary expanded metal mesh according to the present disclosure may be made by perforating, rotary cutting, die cutting or laser cutting a metal sheet with numerous holes. In some embodiments, these holes are generally in the shape of a parallelogram, as discussed above. This method does not increase the area of the metal sheet and generates scrap metal, in the form of a great number of very small pieces, which comprise a large proportion of the original weight of the metal sheet, in many cases more than half the original weight. This method has practical limitations that increase the difficulty of achieving high area coverage, low density, and low strand thickness.

Additional Processing Steps

In some embodiments, methods of making the unitary expanded metal mesh of the present disclosure may additionally comprise steps of flattening, plating, and slitting. Any number of these additional steps may be performed, in any suitable order. Flattening may be accomplished by any suitable method, including without limitation pressing, calendaring and hammering, with application of heat or without application of heat. Plating may be accomplished by any suitable method, including without limitation electroplating, electroless plating, chemical plating, and the like. Slitting may be accomplished by any suitable method, including without limitation the use of cutting tools, blades, lasers, and the like.

Selected Embodiments

The following embodiments, designated by letter and number, are intended to further illustrate the present disclosure but should not be construed to unduly limit this disclosure.

Ml . A unitary expanded metal mesh having a down-roll direction, the mesh comprising:

a) linear strands that are substantially parallel to the down-roll direction; and b) cross strands which meet the linear strands at nodes;

wherein the unitary expanded metal mesh is greater than 3.00 meters in length measured in the down-roll direction.

M2. The unitary expanded metal mesh according to embodiment Ml wherein the linear strands are parallel to the down-roll direction to a tolerance of +/- 10 degrees of angle over the length of the mesh.

M3. The unitary expanded metal mesh according to embodiment M2 wherein the tolerance is +/- 8 degrees of angle over the length of the mesh.

M4. The unitary expanded metal mesh according to embodiment M2 wherein the tolerance is +/- 6 degrees of angle over the length of the mesh.

M5. The unitary expanded metal mesh according to embodiment M2 wherein the tolerance is +/- 5 degrees of angle over the length of the mesh. M6. The unitary expanded metal mesh according to embodiment M2 wherein the tolerance is +/- 4 degrees of angle over the length of the mesh.

M7. The unitary expanded metal mesh according to embodiment M2 wherein the tolerance is +/- 3 degrees of angle over the length of the mesh.

M8. The unitary expanded metal mesh according to embodiment M2 wherein the tolerance is +/- 2 degrees of angle over the length of the mesh. M9. The unitary expanded metal mesh according to any of embodiments M1-M8 wherein the linear strands are parallel to the down-roll direction to a net tolerance of +/- 10 degrees of angle summed over the entire length of the mesh.

M10. The unitary expanded metal mesh according to embodiment M9 wherein the net tolerance is +/- 8 degrees of angle summed over the entire length of the mesh.

Ml 1. The unitary expanded metal mesh according to embodiment M9 wherein the net tolerance is +/- 6 degrees of angle summed over the entire length of the mesh. Ml 2. The unitary expanded metal mesh according to embodiment M9 wherein the net tolerance is +/- 5 degrees of angle summed over the entire length of the mesh.

Ml 3. The unitary expanded metal mesh according to embodiment M9 wherein the net tolerance is +/- 4 degrees of angle summed over the entire length of the mesh.

Ml 4. The unitary expanded metal mesh according to embodiment M9 wherein the net tolerance is +/- 3 degrees of angle summed over the entire length of the mesh.

Ml 5. The unitary expanded metal mesh according to embodiment M9 wherein the net tolerance is +/- 2 degrees of angle summed over the entire length of the mesh. Ml 6. The unitary expanded metal mesh according to any of the preceding embodiments wherein the unitary expanded metal mesh is greater than 4.00 meters in length measured in the down-roll direction. Ml 7. The unitary expanded metal mesh according to any of the preceding embodiments wherein the unitary expanded metal mesh is greater than 6.00 meters in length measured in the down-roll direction.

Ml 8. The unitary expanded metal mesh according to any of the preceding embodiments wherein the unitary expanded metal mesh is greater than 8.00 meters in length measured in the down-roll direction.

Ml 9. The unitary expanded metal mesh according to any of the preceding embodiments wherein the unitary expanded metal mesh is greater than 12.00 meters in length measured in the down-roll direction.

M20. The unitary expanded metal mesh according to any of the preceding embodiments wherein the unitary expanded metal mesh is greater than 52.00 meters in length measured in the down-roll direction.

M21. The unitary expanded metal mesh according to any of the preceding embodiments wherein the unitary expanded metal mesh is greater than 520.00 meters in length measured in the down-roll direction. M22. The unitary expanded metal mesh according to any of the preceding embodiments wherein the unitary expanded metal mesh is greater than 900.00 meters in length measured in the down-roll direction.

M23. The unitary expanded metal mesh according to any of the preceding embodiments wherein the unitary expanded metal mesh is greater than 1400.00 meters in length measured in the down-roll direction. M24. The unitary expanded metal mesh according to any of the preceding embodiments which is a roll having a length of greater than 520.00 meters.

M25. The unitary expanded metal mesh according to any of the preceding embodiments which is a roll having a length of greater than 900.00 meters.

M26. The unitary expanded metal mesh according to any of the preceding embodiments which is a roll having a length of greater than 1400.00 meters. M27. The unitary expanded metal mesh according to any of the preceding embodiments wherein the unitary expanded metal mesh is greater than 1.00 meter in width measured perpendicular to the down-roll direction.

M28. The unitary expanded metal mesh according to any of the preceding embodiments wherein the unitary expanded metal mesh is greater than 2.00 meters in width measured perpendicular to the down-roll direction.

M29. The unitary expanded metal mesh according to any of the preceding embodiments wherein the linear strands and cross strands form a repeating pattern of voids.

M30. The unitary expanded metal mesh according to any of the preceding embodiments wherein the linear strands and cross strands form a repeating pattern of voids substantially in the shape of parallelograms.

M31. The unitary expanded metal mesh according to embodiment M30 wherein the parallelograms have a major axis not parallel or perpendicular to the down-roll direction and the parallelograms have a minor axis not parallel or perpendicular to the down-roll direction.

M32. The unitary expanded metal mesh according to any of the preceding embodiments comprising copper. M33. The unitary expanded metal mesh according to any of the preceding embodiments comprising tin. M34. The unitary expanded metal mesh according to any of the preceding embodiments comprising bronze.

M35. The unitary expanded metal mesh according to any of the preceding embodiments comprising gold.

M36. The unitary expanded metal mesh according to any of the preceding embodiments comprising silver.

M37. The unitary expanded metal mesh according to any of the preceding embodiments comprising nickel.

M38. The unitary expanded metal mesh according to any of the preceding embodiments comprising zinc. M39. The unitary expanded metal mesh according to any of the preceding embodiments comprising iron.

M40. The unitary expanded metal mesh according to any of the preceding embodiments comprising aluminum.

M41. The unitary expanded metal mesh according to any of the preceding embodiments which is plated with nickel.

M42. The unitary expanded metal mesh according to any of the preceding embodiments which is plated with zinc. M43. The unitary expanded metal mesh according to any of the preceding embodiments which is plated with tin.

M44. The unitary expanded metal mesh according to any of the preceding embodiments having a thickness of less than 1.800 mm.

M45. The unitary expanded metal mesh according to any of the preceding embodiments having a thickness of less than 0.800 mm.

M46. The unitary expanded metal mesh according to any of the preceding embodiments having a thickness of less than 0.400 mm.

M47. The unitary expanded metal mesh according to any of the preceding embodiments having a thickness of less than 0.200 mm.

M48. The unitary expanded metal mesh according to any of the preceding embodiments having a thickness of less than 0.040 mm.

M49. The unitary expanded metal mesh according to any of the preceding embodiments having a thickness of less than 0.020 mm.

M50. The unitary expanded metal mesh according to any of the preceding embodiments having a thickness of greater than 0.010 mm.

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

M52. The unitary expanded metal mesh according to any of the preceding embodiments having an average distance between nodes measured along linear strands of less than 4.000 cm. M53. The unitary expanded metal mesh according to any of the preceding embodiments having an average distance between nodes measured along linear strands of less than 0.900 cm. M54. The unitary expanded metal mesh according to any of the preceding embodiments having an average distance between nodes measured along linear strands of less than 0.450 cm.

M55. The unitary expanded metal mesh according to any of the preceding embodiments having an average distance between nodes measured along linear strands of less than 0.200 cm.

M56. The unitary expanded metal mesh according to any of the preceding embodiments having an average distance between nodes measured along linear strands of greater than 0.030 cm.

M57. The unitary expanded metal mesh according to any of the preceding embodiments which is a unitary stretched-expanded metal mesh. CI . A composite material comprising:

c) the unitary expanded metal mesh according to any of embodiments Ml- M37; and

d) a polymeric matrix. C2. The composite material according to embodiment CI, wherein the polymeric matrix is an uncured curable resin.

C3. The composite material according to embodiment CI, wherein the polymeric matrix is a partially cured curable resin.

C4. The composite material according to embodiment CI, wherein the polymeric matrix is a cured curable resin. C5. The composite material according to any of embodiments C1-C4, wherein the polymeric matrix is a thermoset resin. C6. The composite material according to any of embodiments C1-C5, wherein the polymeric matrix is an epoxy resin.

C7. The composite material according to embodiment CI, wherein the polymeric matrix is a thermoplastic resin.

C8. The composite material according to any of embodiments C1-C7, additionally comprising:

e) a woven fiber scrim. C9. The composite material according to embodiment C8, wherein the woven fiber scrim comprises glass fiber.

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

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

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

C13. The composite material according to any of embodiments CI -CI 2, additionally comprising:

f) a non-woven fiber scrim.

C14. The composite material according to embodiment C13, wherein the non-woven fiber scrim comprises glass fiber. CI 5. The composite material according to any of embodiments C13-C14, wherein the non-woven fiber scrim comprises ceramic fiber. C16. The composite material according to any of embodiments C13-C15, wherein the non-woven fiber scrim comprises carbon fiber.

C17. The composite material according to any of embodiments C13-C16, wherein the non-woven fiber scrim comprises polymer fiber.

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

CI 9. The composite material according to any of embodiments CI -CI 7, which is a sheet material having a thickness of less than 3.00 mm.

C20. The composite material according to any of embodiments CI -CI 7, which is a sheet material having a thickness of less than 0.600 mm. C21. The composite material according to any of embodiments CI -CI 7, which is a sheet material having a thickness of less than 0.300 mm.

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

C23. The composite material according to any of embodiments CI -CI 8, which is a sheet material having a thickness of less than 0.040 mm.

PAL A method of making a unitary expanded metal mesh according to any of embodiments M1-M57 comprising the steps of:

g) providing a metal sheet having a down-roll direction; h) simultaneously cutting the metal sheet near its leading edge and bending strands of the metal of the sheet by use of a tool positioned at a diagonal to the down- roll direction of the metal sheet, wherein the cutting comprises cutting a row of slits separated by gaps in the sheet, and wherein the bending comprises bending downward a thin strand of metal of the sheet bordering each slit such that the strand bulges in a direction orthogonal to the plane of the metal sheet;

i) advancing the metal sheet in the down-roll direction; and

j) repeating step h), such that the gaps in adjacent rows of slits fall in a line substantially parallel to the down-roll direction of the metal sheet.

PA2. The method according to embodiment PA1 wherein the tool comprises a plurality of projections extending in a direction orthogonal to the sheet.

PA3. The method according to embodiment PA2 wherein the projections are of a triangular or arcurate shape extending in a direction orthogonal to the sheet.

PA4. The method according to any of embodiments PA1-PA3 wherein the tool is shifted, relative to the lateral position of the sheet, between two alternate positions with each repetition of step h).

PA5. The method according to any of embodiments PA1-PA3 wherein the tool is not shifted, relative to the lateral position of the sheet, between repetitions of step h).

PA6. The method according to any of embodiments PA1-PA5 wherein the row of slits is a row of parallel slits.

PA7. The method according to any of embodiments PA1-PA5 wherein the row of slits is a row of co-linear slits. PA8. The method according to any of embodiments PA1-PA7 wherein the step of providing a metal sheet having a down-roll direction comprises providing a roll of metal sheet having a down-roll direction parallel to the long side of the rolled metal sheet.

PA9. The method according to embodiment PA8 which is a continuous process by roll.

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

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

PB1. A method of making a unitary expanded metal mesh according to any of embodiments M1-M57 comprising the steps of:

p) providing a metal sheet having a down-roll direction;

q) slitting the sheet to form a slit metal sheet bearing a plurality of rows of slits separated by gaps, wherein the rows of slits are oriented at a diagonal to the down-roll direction of the sheet and wherein the gaps in adjacent rows of slits fall in a line substantially parallel to the down-roll direction of the metal sheet.

PB2. The method according to embodiment PB1 additionally comprising the step of: r) stretching the slit metal sheet in a direction not parallel to the down-roll direction of the metal sheet to form the unitary expanded metal mesh.

PB3. The method according to any of embodiments PB 1-PB2 wherein the row of slits is a row of parallel slits.

PB4. The method according to any of embodiments PB 1-PB2 wherein the row of slits is a row of co-linear slits. PB5. The method according to any of embodiments PB1-PB4 wherein the step of providing a metal sheet having a down-roll direction comprises providing a roll of metal sheet having a down-roll direction parallel to the long side of the rolled metal sheet.

PB6. The method according to embodiment PB5 which is a continuous process by roll.

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

PB8. The method according to any of embodiments PB5-PB6 wherein the roll of metal sheet has a length of greater than 520.00 meters. PPMl . A unitary metal mesh having a down-roll direction, the mesh comprising:

wherein the unitary metal mesh is greater than 3.00 meters in length measured in the down-roll direction.

PM2. The unitary metal mesh according to embodiment PM1 wherein the linear strands are parallel to the down-roll direction to a tolerance of +/- 10 degrees of angle over the length of the mesh. PM3. The unitary metal mesh according to embodiment PM2 wherein the tolerance is +/- 8 degrees of angle over the length of the mesh.

PM4. The unitary metal mesh according to embodiment PM2 wherein the tolerance is +/- 6 degrees of angle over the length of the mesh.

PM5. The unitary metal mesh according to embodiment PM2 wherein the tolerance is +/- 5 degrees of angle over the length of the mesh. PM6. The unitary metal mesh according to embodiment PM2 wherein the tolerance is +/- 4 degrees of angle over the length of the mesh. PM7. The unitary metal mesh according to embodiment PM2 wherein the tolerance is +/- 3 degrees of angle over the length of the mesh.

PM8. The unitary metal mesh according to embodiment PM2 wherein the tolerance is +/- 2 degrees of angle over the length of the mesh.

PM9. The unitary metal mesh according to any of embodiments PM1-PM8 wherein the linear strands are parallel to the down-roll direction to a net tolerance of +/- 10 degrees of angle summed over the entire length of the mesh. PM10. The unitary metal mesh according to embodiment PM9 wherein the net tolerance is +/- 8 degrees of angle summed over the entire length of the mesh.

PM11. The unitary metal mesh according to embodiment PM9 wherein the net tolerance is +/- 6 degrees of angle summed over the entire length of the mesh.

PM12. The unitary metal mesh according to embodiment PM9 wherein the net tolerance is +/- 5 degrees of angle summed over the entire length of the mesh.

PM13. The unitary metal mesh according to embodiment PM9 wherein the net tolerance is +/- 4 degrees of angle summed over the entire length of the mesh.

PM14. The unitary metal mesh according to embodiment PM9 wherein the net tolerance is +/- 3 degrees of angle summed over the entire length of the mesh.

PM15. The unitary metal mesh according to embodiment PM9 wherein the net tolerance is +/- 2 degrees of angle summed over the entire length of the mesh. PM16. The unitary metal mesh according to any of the preceding embodiments wherein the unitary metal mesh is greater than 4.00 meters in length measured in the down-roll direction. PM17. The unitary metal mesh according to any of the preceding embodiments wherein the unitary metal mesh is greater than 6.00 meters in length measured in the down-roll direction.

PM18. The unitary metal mesh according to any of the preceding embodiments wherein the unitary metal mesh is greater than 8.00 meters in length measured in the down-roll direction.

PM19. The unitary metal mesh according to any of the preceding embodiments wherein the unitary metal mesh is greater than 12.00 meters in length measured in the down-roll direction.

PM20. The unitary metal mesh according to any of the preceding embodiments wherein the unitary metal mesh is greater than 52.00 meters in length measured in the down-roll direction.

PM21. The unitary metal mesh according to any of the preceding embodiments wherein the unitary metal mesh is greater than 520.00 meters in length measured in the down-roll direction. PM22. The unitary metal mesh according to any of the preceding embodiments wherein the unitary metal mesh is greater than 900.00 meters in length measured in the down-roll direction.

PM23. The unitary metal mesh according to any of the preceding embodiments wherein the unitary metal mesh is greater than 1400.00 meters in length measured in the down-roll direction. PM24. The unitary metal mesh according to any of the preceding embodiments which is a roll having a length of greater than 520.00 meters.

PM25. The unitary metal mesh according to any of the preceding embodiments which is a roll having a length of greater than 900.00 meters.

PM26. The unitary metal mesh according to any of the preceding embodiments which is a roll having a length of greater than 1400.00 meters. PM27. The unitary metal mesh according to any of the preceding embodiments wherein the unitary metal mesh is greater than 1.00 meter in width measured perpendicular to the down-roll direction.

PM28. The unitary metal mesh according to any of the preceding embodiments wherein the unitary metal mesh is greater than 2.00 meters in width measured perpendicular to the down-roll direction.

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

PM30. The unitary metal mesh according to any of the preceding embodiments wherein the linear strands and cross strands form a repeating pattern of voids substantially in the shape of parallelograms. PM31. The unitary metal mesh according to embodiment PM30 wherein the parallelograms have a major axis not parallel or perpendicular to the down-roll direction and the parallelograms have a minor axis not parallel or perpendicular to the down-roll direction. PM32. The unitary metal mesh according to any of the preceding embodiments comprising copper. PM33. The unitary metal mesh according to any of the preceding embodiments comprising tin.

PM34. The unitary metal mesh according to any of the preceding embodiments comprising bronze.

PM35. The unitary metal mesh according to any of the preceding embodiments comprising gold. PM36. The unitary metal mesh according to any of the preceding embodiments comprising silver.

PM37. The unitary metal mesh according to any of the preceding embodiments comprising nickel.

PM38. The unitary metal mesh according to any of the preceding embodiments comprising zinc.

PM39. The unitary metal mesh according to any of the preceding embodiments comprising iron.

PM40. The unitary metal mesh according to any of the preceding embodiments comprising aluminum. PM41. The unitary metal mesh according to any of the preceding embodiments which is plated with nickel.

PM42. The unitary metal mesh according to any of the preceding embodiments which is plated with zinc.

PM43. The unitary metal mesh according to any of the preceding embodiments which is plated with tin. PM44. The unitary metal mesh according to any of the preceding embodiments having a thickness of less than 1.800 mm. PM45. The unitary metal mesh according to any of the preceding embodiments having a thickness of less than 0.800 mm.

PM46. The unitary metal mesh according to any of the preceding embodiments having a thickness of less than 0.400 mm.

PM47. The unitary metal mesh according to any of the preceding embodiments having a thickness of less than 0.200 mm.

PM48. The unitary metal mesh according to any of the preceding embodiments having a thickness of less than 0.040 mm.

PM49. The unitary metal mesh according to any of the preceding embodiments having a thickness of less than 0.020 mm. PM50. The unitary metal mesh according to any of the preceding embodiments having a thickness of greater than 0.010 mm.

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

PM52. The unitary metal mesh according to any of the preceding embodiments having an average distance between nodes measured along linear strands of less than 4.000 cm. PM53. The unitary metal mesh according to any of the preceding embodiments having an average distance between nodes measured along linear strands of less than 0.900 cm. PM54. The unitary metal mesh according to any of the preceding embodiments having an average distance between nodes measured along linear strands of less than 0.450 cm.

PM55. The unitary metal mesh according to any of the preceding embodiments having an average distance between nodes measured along linear strands of less than 0.200 cm. PM56. The unitary metal mesh according to any of the preceding embodiments having an average distance between nodes measured along linear strands of greater than 0.030 cm.

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

Claims

We claim:

1. A unitary expanded metal mesh having a down-roll direction, the mesh comprising:

2. The unitary expanded metal mesh according to claim 1 wherein the linear strands are parallel to the down-roll direction to a tolerance of +/- 10 degrees of angle over the length of the mesh.

3. The unitary expanded metal mesh according to any of claims 1-2 wherein the linear strands are parallel to the down-roll direction to a net tolerance of +/- 10 degrees of angle summed over the entire length of the mesh.

4. The unitary expanded metal mesh according to any of the preceding claims wherein the unitary expanded metal mesh is greater than 8.00 meters in length measured in the down-roll direction.

5. The unitary expanded metal mesh according to any of the preceding claims wherein the unitary expanded metal mesh is greater than 900.00 meters in length measured in the down-roll direction.

6. The unitary expanded metal mesh according to any of the preceding claims comprising a metal selected from the group consisting of copper, tin, gold, silver, nickel, zinc, iron, aluminum and alloys thereof.

7. The unitary expanded metal mesh according to any of the preceding claims having a thickness of less than 1.800 mm and greater than 0.010 mm.

8. The unitary expanded metal mesh according to any of the preceding claims having an average distance between nodes measured along linear strands of less than 4.000 cm and greater than 0.030 cm.

9. The unitary expanded metal mesh according to any of the preceding claims which is a unitary stretched-expanded metal mesh.

10. A composite material comprising:

c) the unitary expanded metal mesh according to any of claims 1-9; and d) a polymeric matrix.

11. The composite material according to claim 10, wherein the polymeric matrix is an uncured curable resin or a partially cured curable resin.

12. The composite material according to any of claims 10-11, wherein the polymeric matrix is an epoxy resin.

13. The composite material according to any of claims 10-12, additionally comprising one or both of:

e) a woven fiber scrim; or

f) a non-woven fiber scrim.

14. The composite material according to any of claims 10-13, which is a sheet material having a thickness of less than 6.00 mm and greater than 0.020 mm.

15. A method of making a unitary expanded metal mesh according to any of claims 1-9 comprising the steps of :

g) providing a metal sheet having a down-roll direction;

h) simultaneously cutting the metal sheet near its leading edge and bending strands of the metal of the sheet by use of a tool positioned at a diagonal to the down- roll direction of the metal sheet, wherein the cutting comprises cutting a row of slits separated by gaps in the sheet, and wherein the bending comprises bending downward a thin strand of metal of the sheet bordering each slit such that the strand bulges in a direction orthogonal to the plane of the metal sheet;

i) advancing the metal sheet in the down-roll direction; and

16. The method according to claim 15 wherein the tool comprises a plurality of projections extending in a direction orthogonal to the sheet, wherein the projections are of a triangular or arcurate shape, and wherein the row of slits is a row of co-linear slits.

17. The method according to any of claims 15-16 wherein the tool is shifted, relative to the lateral position of the sheet, between two alternate positions with each repetition of step h).

18. The method according to any of embodiments 15-16 wherein the tool is not shifted, relative to the lateral position of the sheet, between repetitions of step h).

19. A method of making a unitary expanded metal mesh according to any of embodiments 1-9 comprising the steps of:

p) providing a metal sheet having a down-roll direction;

q) slitting the sheet to form a slit metal sheet bearing a plurality of rows of slits separated by gaps, wherein the rows of slits are oriented at a diagonal to the down-roll direction of the sheet and wherein the gaps in adjacent rows of slits fall in a line substantially parallel to the down-roll direction of the metal sheet; and

r) stretching the slit metal sheet in a direction not parallel to the down-roll direction of the metal sheet to form the unitary expanded metal mesh.

20. The method according to claim 19 wherein the row of slits is a row of co-linear slits.

21. The method according to any of claims 10-20 wherein the step of providing a metal sheet having a down-roll direction comprises providing a roll of metal sheet having a down-roll direction parallel to the long side of the rolled metal sheet.

22. The method according to claim 21 which is a continuous process by roll.

23. A unitary metal mesh having a down-roll direction, the mesh comprising:

24. The unitary metal mesh according to claim 23, wherein the unitary metal mesh is greater than 900.00 meters in length measured in the down-roll direction.