Flattened Wire Mesh Tabs to Prevent Rolled-Memory Curling
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Solution Overview
Problem
Wire meshes with continuous transverse wires often exhibit circular memory when rolled, leading to tabs projecting away from the substrate during installation, which complicates flat laying and requires additional tensioning or fastening, especially when used for applications like stucco lath.
Innovation Solution
A wire mesh design featuring a monolithic transverse member with elongate transverse and longitudinal portions, where the longitudinal portions are positioned outside the area between the outermost longitudinal members, and a force is applied to these portions to deform them, ensuring they remain flat when installed.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If continuous transverse wires are used to form wire mesh, then high operating speeds can be achieved, but circular memory occurs when the wire mesh is rolled, causing tabs to project away from the substrate
Solution Approach 1:
The patent applies preliminary action by flattening the tabs during the manufacturing process before the wire mesh is rolled or installed. The flattening operation pre-combats the circular memory effect that will occur during rolling, ensuring the tabs remain flat during installation rather than projecting away from the substrate.
Solution Approach 2:
The patent applies preliminary anti-action by applying a flattening force to the tabs that opposes the circular memory effect. This counteracting force is applied in advance during manufacturing, creating a pre-flattened state that resists the tendency of tabs to curl or project when the mesh is rolled or installed.
2Loss of substance
If tabs are trimmed off adjacent to outermost longitudinal wires, then scrap loss is reduced, but operating speed decreases due to additional trimming step
Solution Approach 1:
The patent applies the taking out principle by removing only the excess portion of the tabs that extend beyond the outermost longitudinal wires, while retaining the functional portion of the tabs within the mesh area. This selective removal eliminates scrap loss from excessive tab length without requiring complete tab removal, maintaining both material efficiency and operational speed.
3Ease of manufacture
If tabs are left intact as part of finished wire mesh, then most economical combination is achieved, but tabs exhibit circular memory when rolled
Solution Approach 1:
The patent applies preliminary action by incorporating a flattening step during manufacturing that prepares the tabs for their future rolled state. The tabs are flattened in advance, creating a pre-conditioned state that maintains flatness during installation even though the tabs remain intact as part of the finished mesh.
Solution Approach 2:
The patent applies parameter changes by modifying the physical state of the tabs through flattening, changing their shape parameters from curled or irregular to flat and uniform. This parameter modification allows the tabs to remain intact while eliminating the circular memory effect that would otherwise cause them to project during installation.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution allows wire meshes to lay flat against substrates without the need for excessive tensioning or additional fasteners, maintaining quality and reducing waste, even with longer tabs or larger wire diameters, thus improving installation efficiency and product quality.
Implementation Method 1
a force is applied to these portions to deform them, ensuring they remain flat when installed
Data Source
AI summary
A manufacturing assembly and method produce a wire mesh including a plurality of longitudinal members and a monolithic transverse member secured to the plurality of longitudinal members. The monolithic transverse member includes a plurality of transverse portions that define a first cross-sectional shape, and further includes a plurality of longitudinal portions that define a second cross-sectional shape different than the first cross-sectional shape.