Tooling and method of manufacturing a mesh laminate
View Patent ↗An apparatus and method of manufacturing a wire mesh laminate includes wrapping a central core with multiple layers of mesh screen and a barrier layer having a higher melting point than the mesh screen to form a spool assembly. The spool assembly is then surrounded by an outer cover and is heated to sinter or fuse together the layers of mesh screen.
1. A method of manufacturing a mesh laminate screen, comprising:
wrapping a plurality of mesh layers and a barrier layer around a central core to form an assembly, wherein the barrier layer comprises a material having a higher melting point than the plurality of mesh layers;
heating the assembly; and
forming the mesh laminate screen.
2. The method of claim 1 , further comprising restraining expansion of the assembly.
3. The method of claim 2 , wherein restraining expansion of the assembly comprises disposing a cover around the assembly.
4. The method of claim 3 , wherein the cover comprises a material having a relatively low coefficient of thermal expansion.
5. The method of claim 3 , wherein the cover comprises a first portion coupled to a second portion.
6. The method of claim 5 , wherein the first portion is coupled to the second portion using one or more bolts.
7. The method of claim 3 , wherein an inner diameter of the cover is smaller than an outer diameter of the assembly.
8. The method of claim 1 , further comprising disposing a second barrier layer around the central core before wrapping the plurality of mesh layers.
9. The method of claim 8 , further comprising surrounding the assembly with a third barrier layer.
10. The method of claim 9 , further comprising banding the third barrier layer around the assembly.
11. The method of claim 10 , further comprising surrounding the banded assembly with a fourth barrier layer.
12. The method of claim 9 , wherein one or more of the barrier layers comprises a material having a higher melting point than the plurality of mesh layers.
13. The method of claim 1 , wherein the central core comprises a material having a relatively high coefficient of thermal expansion.
14. The method of claim 13 , wherein the central core has a higher coefficient of thermal expansion than a coefficient of thermal expansion of the cover.
15. The method of claim 1 , wherein the plurality of mesh layers comprise stainless steel.
16. The method of claim 15 , wherein the barrier layer comprises a material selected from the group consisting of molybdenum, tungsten, ceramic, and combinations thereof.
17. The method of claim 15 , wherein the assembly is heated between about 2,150° F. to about 2,350° F.
18. The method of claim 1 , wherein the assembly is heated between about 70% to about 90% of the melting point of the plurality of mesh layers.
19. The method of claim 1 , wherein the assembly is heated in a heating atmosphere selected from the group consisting of a gas, a gas mixture, a vacuum, and combinations thereof.
20. The method of claim 1 , wherein the assembly is heated in a heating atmosphere having a gas selected from the group consisting of hydrogen, nitrogen, and combinations thereof.
21. The method of claim 1 , wherein the central core comprises one or more perforations.
22. The method of claim 1 , further comprising fusing the plurality of mesh layers together.
23. A method of manufacturing a sintered mesh laminate, comprising:
surrounding a first barrier layer around a central core;
wrapping a plurality of mesh layers and a second barrier layer around the central core;
disposing a cover around the plurality of mesh layers and the second barrier layer, wherein the first and second barrier layers comprise a material having a higher melting point than the mesh layers; and
heating the cover and the plurality of mesh layers.
24. The method of claim 23 , wherein the central core is expanded upon heating.
25. The method of claim 24 , wherein the expansion exerts a pressure against the plurality of mesh layers.
26. The method of claim 25 , wherein the plurality of mesh layers is at least partially fused together.
27. The method of claim 23 , wherein the cover and the spool assembly are heated in a heating atmosphere selected from the group consisting of a gas, a gas mixture, a vacuum, and combinations thereof.
28. The method of claim 23 , wherein the cover and the plurality of mesh layers are heated between about 2,150° F. to about 2,350° F.
29. The method of claim 23 , wherein the cover and the plurality of mesh layers are heated between about 50% to about 95% of the melting point of the plurality of mesh layers.
30. The method of claim 23 , wherein the cover and the plurality of mesh layers are heated between about 70% to about 90% of the melting point of the plurality of mesh layers.
31. A method of manufacturing a mesh laminate, comprising:
wrapping a plurality of mesh layers and a barrier layer around a central core to form an assembly;
wherein the barrier layer comprises a material having a higher melting point than the plurality of mesh layers;
heating the assembly; and
forming the mesh laminate.
32. A method of manufacturing a mesh laminate, comprising:
wrapping a plurality of mesh layers and a barrier layer around a central core to form an assembly;
heating the assembly;
forming the mesh laminate;
disposing a second barrier layer around the central core before wrapping the plurality of mesh layers; and
surrounding the assembly with a third barrier layer.
33. The method of claim 32 , further comprising banding the third barrier layer around the assembly.
34. The method of claim 33 , further comprising surrounding the banded assembly with a fourth barrier layer.
35. The method of claim 32 , wherein one or more of the barrier layers comprises a material having a higher melting point than the plurality of mesh layers.
36. A method of manufacturing a mesh laminate screen, comprising:
forming an assembly comprising;
disposing a first barrier layer around a central core;
wrapping a plurality of mesh layers and a second barrier layer around the central core;
surrounding the central core with a third barrier layer;
heating the assembly; and
forming the mesh laminate screen.
37. The method of claim 36 , further comprising surrounding the banded assembly with a fourth barrier layer.
38. The method at claim 36 , wherein one or more of the barrier layers comprises a material having a higher melting point than the plurality of mesh layers.