Process for producing high quality metallic fiber mesh

Details Process for producing high quality metallic fiber mesh Process for producing high quality metallic fiber mesh

2001-09-10

2002-05-07

Bryant, David P. (Department: 3726)

Metal working

Method of mechanical manufacture

Shaping fiber or fibered material

C029S424000, C029S423000

Reexamination Certificate

active

06381826

ABSTRACT:

BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to metallic tow or metallic threads and more particularly to an apparatus and method of producing high quality metallic mesh from an array of metallic threads made from fine metallic fibers.
2. Description of the Related Art
This invention relates to metallic mesh or metallic fiber cord and more particularly to an improved apparatus and method of producing high quality metallic mesh or metallic fabric from an array of fine metallic fibers. Metallic mesh is generally formed from a matrix of metallic fiber tow or continuous metallic cord. The metallic fiber tow or continuous metallic cord is characterized as an array of parallel metallic fibers forming a continuous cord of a suitable length. Typically, each of the metallic fibers of the mesh is less than 50 microns in diameter. The metallic fiber tow normally includes continuous metallic fibers in a quantity greater than 19 parallel metallic fibers.
The production of high quality metallic fiber tow is a more difficult task than the production of high quality chopped metallic fibers. Typically, chopped metallic fibers have a length of less than 2 to 3 centimeters. Both metallic fiber tow and metallic chopped fibers are formed in a similar manner. The metallic fibers are formed by cladding an array of metallic wires and drawing the clad array to reduce the outer diameter thereof and to reduce the corresponding diameters of the array of metallic wires thereby producing an array of metallic fibers. The clad array of metallic fibers is chopped into cladding sections of less than two to three centimeters. The chopped cladding sections are placed into a leaching bath to remove the cladding material thereby producing chopped metallic fibers.
The metallic fiber tow is a more difficult task to produce than chopped metallic fibers since clad metallic fiber tow is more difficult to leach than chopped clad metallic fibers. The metallic fiber tow is made in a similar fashion with the exception that the continuous cladding of continuous metallic fibers must be leached as a continuous cladding of metallic fiber tow. The prior art has utilized two methods of leaching the continuous cladding of metallic fiber tow, namely the continuous leaching process and the batch leaching process. In the continuous leaching process, the continuous cladding of metallic fiber tow is passed through a longitudinally extending leaching bath thereby giving a chemical agent sufficient time to remove the cladding material leaving the continuous metallic fiber tow. This process necessitated the use of a long leaching bath, which was unsatisfactory in many cases. Secondly, the continuous cladding of metallic fiber tow had to be pulled through the longitudinally extending leaching tank thereby placing substantial stress on the metallic fiber tow after removal of the cladding material. This substantial stress on the metallic fiber tow resulted in breakage of some of the metallic fibers in the metallic fiber tow thereby reducing the quality thereof.
The second method of leaching the continuous cladding of metallic fiber tow was through a batch process. In the batch process, the continuous cladding of metallic fiber tow was reeled onto a leaching spool and placed in a leaching bath. In order to prevent the individual metallic fibers of one winding of the metallic fiber tow from being entangled with individual metallic fibers of an adjacent winding the continuous cladding of metallic fiber tow was twisted as the continuous cladding of metallic fiber tow was reeled onto the leaching spool.
After the batch leaching process, the continuous cladding of metallic fiber tow was unreeled from the leaching spool and placed on a transport spool or for ultimate use. Unfortunately, the twisting of the continuous metallic fiber tow did not totally prevent the individual metallic fibers of one winding of the metallic fiber tow from being entangled with individual metallic fibers of an adjacent winding of the continuous metallic fiber tow. Accordingly, the unreeling of the continuous metallic fiber tow from the leaching spool resulted in breakage of some of the individual metallic fibers thereby providing poor quality fiber tow.
In some instances, the continuous metallic fiber tow was used in the production of high quality metallic mesh. Many processes have been known in the prior art for the manufacture and production of high quality metallic mesh. Among the prior art that have attempted to provide for the manufacturing and production of high quality metallic fiber tow and/or high quality metallic mesh are the following United States patents.
U.S. Pat. No. 2,050,298 to Everett discloses a process for the production of stranded wire by reduction from elements of comparatively large cross-sections. The process comprises the steps of assembling of a plurality of the elements in side-by-side relationship. The encased assembly of elements is reduced thus formed as a unit and imparting a permanent helical twist to the reduced bundle and then removing the casing.
U.S. Pat. No. 3,505,039 to Roberts et al. discloses a product defined as fine metal filaments, such as filaments of under approximately 15 microns diameter, in long lengths wherein a plurality of sheathed elements are first constricted to form a reduced diameter billet by means of hot forming. After the hot forming constriction, the billet is then drawn to the final size wherein the filaments have the desired final small diameter. The material surrounding the filaments is then removed by suitable means leaving the filaments in the form of a tow.
U.S. Pat. No. 3,540,114 to Roberts et al. discloses a method of forming fine filaments formed of a material such as metal by multiple end drawing a plurality of elongated elements having thereon a thin film of lubricant material. The plurality of elements may be bundled in a tubular sheath formed of drawable material. The lubricant may be applied to the individual elements prior to the bundling thereof and may be provided by applying the lubricant to the elements while they are being individually drawn through a coating mechanism such as a drawing die. The lubricant comprises a material capable of forming a film having a high tenacity characteristic whereby the film is maintained under the extreme pressure conditions of drawing process. Upon completion of the constricting operation, the tubular sheath is removed. If desired, the lubricant may be also removed from the resultant filaments.
U.S. Pat. No. 3,698,863 to Roberts et al. discloses a metallic filament that has an effective diameter of less than 50 microns and is formed while surrounded by a subsequently removed sacrificial matrix. The filament has a preselected peripheral surface varying from substantially smooth to re-entrant and a preselected surface to volume ratio. The area of the filament also has a controlled non-uniformity along the length thereof which provides an acceptable dimensional tolerance. The metallic filament may be substantially one metal, bimetallic or tubular.
U.S. Pat. No. 3,977,069 to Domaingue, Jr. discloses that this invention contemplates a method and apparatus for taking fine metal fibers having a diameter range from 0.5 microns to approximately 150 microns and cutting the fibers into precise short lengths. The method and apparatus comprises first moistening tows of metal fibers and unwinding the tows from spools and positioning them into tow bands. A stiffened ribbon made from the tow bands is cut to the desired precise lengths in order to prevent cold welding or deformation of the ends of the fibers during the cutting operation. Materials that may be used for stiffening the fibers include starch, PCA, ice, etc.
U.S. Pat. No. 3,977,070 to Schildbach discloses the method of forming a tow of filaments wherein a bundle of elongated elements such as rods or wires, is clad by forming a sheath of material different from that of the elements about the bundle. The bundle is subsequently drawn to constrict the elements to a desired small diame

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