Unitary expanded metal mesh having linear down-roll strands

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.

1 . 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. 
     
     
         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  claim 1  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  claim 1  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  claim 1  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  claim 1  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  claim 1  having a thickness of less than 1.800 mm and greater than 0.010 mm. 
     
     
         8 . The unitary expanded metal mesh according to  claim 1  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  claim 1  which is a unitary stretched-expanded metal mesh. 
     
     
         10 . A composite material comprising:
 c) the unitary expanded metal mesh according to  claim 1 ; 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 . (canceled) 
     
     
         13 . The composite material according to  claim 10 , additionally comprising one or both of:
 e) a woven fiber scrim; or   f) a non-woven fiber scrim.   
     
     
         14 . The composite material according to  claim 10 , 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  claim 1  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. 
 
     
     
         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 arcuate shape, and wherein the row of slits is a row of co-linear slits. 
     
     
         17 . The method according to  claim 15  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  claim 15  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  claim 1  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  claim 10  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 - 24 . (canceled)