MESH SHEET, SYSTEMS AND DEVICES THAT INCORPORATE A MESH SHEET, AND METHODS AND EQUIPMENT FOR FABRICATING A MESH SHEET

Abstract

An apparatus for manufacturing a second mesh roll from a first mesh roll is disclosed. The apparatus comprises an unreeling shaft, an edge treatment unit, and a reeling shaft. The unreeling shaft is configured to rotatably support the first mesh roll and provide an unreeled length of the first mesh roll in a longitudinal direction. The edge treatment unit is configured to receive the unreeled length of the first mesh roll and cut the first mesh roll along a transverse axis and treat one or more edges of the first mesh roll to form the second mesh roll. The reeling shaft is configured to receive and rotatably support the second mesh roll.

Description

INTRODUCTION

Aspects of this disclosure relate generally to a mesh sheet, systems that incorporate a mesh sheet, and processes for fabricating a mesh sheet.

The transport and storage of combustible substances presents several inherent problems. Such problems include safety concerns such as the risk of fire and explosion, as well as environmental concerns stemming from the unavoidable evaporation of volatile liquids. The safety concerns pose a significant hazard to life and property, especially in the case of large tank farms located near populated areas, or in military applications, where vehicles are under threat, and detonation of fuel tanks from enemy ordnance is an ever-present risk. Additionally, the evaporation of fuel presents not only environmental problems but presents significant costs due to fuel loss.

SUMMARY

The following summary is an overview provided solely to aid in the description of various aspects of the disclosure and is provided solely for illustration of the aspects and not limitation thereof.

The present disclosure relates to a mesh foil product with specific properties. For example, the mesh foil may be an expanded mesh foil product made of aluminum alloy. The mesh foil product may further have hexagonal geometric openings. Expanded metal mesh rolls typically have edges that are susceptible to fraying and deterioration. This can lead to a degradation of the metal mesh roll and can also lead to loose fragments of metal mesh in the container where the roll is disposed. These fragments can clog fuel lines or other conduits in communication with the container. The present disclosure further relates to solutions for mitigating such problems.

According to at least one exemplary embodiment, apparatus for treating an edge of an expanded metal mesh may be disclosed. The apparatus can include a cutting device, an engagement plate, at least one protective plate delivery arm, a welding device having a welding horn and an anvil, the engagement plate adapted to position the edge of the expanded metal mesh proximate the horn and the anvil, the at least one protective plate delivery arm adapted to position a protective plate proximate the horn and the anvil, the welding device adapted to weld the protective plate to the edge of the expanded metal mesh.

According to another exemplary embodiment, an expanded metal mesh roll is disclosed. The expanded metal mesh roll, can include an expanded metal mesh, the mesh being wound such that a first transverse edge of the mesh is disposed at the interior of the roll and a second transverse edge of the mesh is disposed at the exterior of the roll, wherein the mesh is formed by stretching a metal sheet having a plurality of slits cut therein, the slits being oriented parallel to the longitudinal axis of the aluminum sheet. The expanded metal mesh roll can further include a protective plate welded to the second transverse edge of the mesh.

The present disclosure further relates to various systems and devices that incorporate an expanded aluminum foil mesh with hexagonal openings in specific form and shape, such as air filters, mufflers, smokestacks, electric appliances, IT equipment, computers, servers, and building wall units.

According to an exemplary embodiment, an apparatus for storing a combustible liquid and suppressing the combustion of the liquid is disclosed. The apparatus can include an inner cavity for the storage of combustible liquid, at least one roll disposed within the cavity, the roll formed from an expanded metal mesh, wherein the mesh is formed from a stretched metal sheet having a plurality of slits cut therein, the slits being oriented parallel to the longitudinal axis of the aluminum sheet.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings are presented to aid in the description of various aspects of the disclosure and are provided solely for illustration of the aspects and not limitation thereof.

FIG. 1a generally illustrates an example embodiment of a mesh sheet.

FIG. 1b is a detail view of the mesh sheet of FIG. 1a.

FIG. 1c is a partial cross-sectional view along a transverse axis of the mesh sheet of FIG. 1a.

FIG. 1d is a view of a longitudinal edge of the mesh sheet of FIG. 1a.

FIG. 2 generally illustrates an example embodiment of a mesh foil arranged in a roll shape.

FIG. 3 generally illustrates an example embodiment of a muffler having mesh foil disposed therein.

FIG. 4 generally illustrates an example embodiment of a wall container having mesh foil disposed therein.

FIG. 5a generally illustrates an example embodiment of a computer having mesh foil disposed therein.

FIG. 5b generally illustrates an example embodiment of a server having mesh foil disposed therein.

FIG. 6 generally illustrates an exemplary embodiment of a mesh roll.

FIG. 7 generally illustrates an exemplary embodiment of a container having a mesh roll disposed therein.

FIG. 8 generally illustrates an exemplary container wherein the container is a fuel tank.

FIG. 9 generally illustrates an exemplary container wherein the container is a jerry can.

FIG. 10 generally illustrates an exemplary container wherein the container is a tanker trailer.

FIG. 11 generally illustrates an exemplary container wherein the container is a fuel tank of a watercraft.

FIG. 12a generally illustrates a perspective view of an exemplary embodiment of a reeling-unreeling machine.

FIG. 12b generally illustrates a side view of an exemplary embodiment of a reeling-unreeling machine.

FIG. 12c generally illustrates an end view of an exemplary embodiment of a reeling-unreeling machine.

FIG. 12d generally illustrates a top view of an exemplary embodiment of a reeling-unreeling machine.

FIG. 13a generally illustrates a perspective view of an exemplary embodiment of an edge treatment unit.

FIG. 13b generally illustrates a top view of an exemplary embodiment of an edge treatment unit.

FIG. 14a generally illustrates a side view of an exemplary embodiment of an edge treatment unit.

FIG. 14b generally illustrates another side view of an exemplary embodiment of an edge treatment unit.

FIG. 15a generally illustrates a perspective view of an exemplary embodiment of a protective plate.

FIG. 15b generally illustrates a side view of an exemplary embodiment of a protective plate.

FIG. 15c generally illustrates another side view of an exemplary embodiment of a protective plate.

FIG. 15d generally illustrates a side view of another exemplary embodiment of a protective plate.

DETAILED DESCRIPTION

FIG. 1a generally illustrates an example embodiment of a mesh sheet 100. The mesh sheet 100 may be formed as mesh foil. The mesh sheet 100 may be an expanded metal foil mesh comprising, for example, an aluminum alloy. The composition of the aluminum alloy foil used for mesh sheet 100 may include up to 0.25% Si, up to 0.40% Fe, up to 0.10% Cu, up to 0.10% Mn, between 2.20% and 2.40% Mg, up to 0.15% Cr, up to 0.10% Zn, and the remainder Al. Additionally, in some embodiments, the alloy may further include up to 0.15% of other metals, if desired, with each of these other metals being no more than 0.005% of the composition of the alloy.

The mesh sheet 100 may include a plurality of apertures 110. The apertures 110 may be substantially hexagonally shaped. In some embodiments, the spacing between the slits may be approximately 2 mm to approximately 3 mm in a longitudinal direction (left and right in FIG. 1a), and approximately 1.0 mm to 1.5 mm in the transverse direction (up and down in FIG. 1a).

FIG. 1b is a detail view of the mesh sheet 100 of FIG. 1a. As shown in FIG. 1b, the apertures may be oriented such that the axis 112 between a pair of opposite vertices 114 of each aperture 110 is disposed parallel to the longitudinal axis 116 of the mesh sheet 100. Apertures 110 may be bounded by continuous metal strips 118, all strips 118 having substantially the same widths with respect to each other. In some embodiments, the widths of the strips 118 may be approximately 1.0 mm to 1.5 mm.

FIG. 1c is a partial cross-sectional view along a transverse axis of the mesh sheet 100 of FIG. 1a. As shown in FIG. 1c, the transverse axes 120 of strips 118 may be oriented obliquely to the plane of mesh sheet 100, so as to present a substantially stepped configuration. Mesh sheet 100 may have any desired length or width, which may depend on the desired application of mesh sheet 100, for example the volume, shape, and configuration of the container in which rolls of mesh sheet 100 may be disposed. In some embodiments, the sheet of metal foil from which mesh sheet 100 is formed may have a width between approximately 75 mm and approximately 125 mm, with the sheet then being stretched to a desired width. Furthermore, the sheet of metal foil may have a thickness of approximately 70 μm, as thinner sheets may be unstable, while thicker sheets may be stiffer, have greater weight, and occupy a greater volume without increasing the efficacy of the mesh.

FIG. 1d is a view of a longitudinal edge of the mesh sheet 100 of FIG. 1a. In some embodiments, the longitudinal edges 122 of expanded metal mesh sheet 100 may be crimped so as to reduce the likelihood of fraying of mesh sheet 100 at the longitudinal edges 122, thereby preventing the detachment of mesh particles from mesh sheet 100. The edges 122 may be crimped so as to present an undulating profile, as shown in FIG. 1d. Crimping of edges 122 may be accomplished during the manufacturing process of mesh sheet 100, or may be performed post-manufacture.

A variety of embodiments for different industries may be constructed around the mesh sheet 100, which may be incorporated in different forms (e.g., in the form of rolls, straight sheets, etc.) depending on the particular application.

FIG. 2 generally illustrates an example embodiment of a mesh sheet provided in a roll-shaped arrangement 200. As will be understood from FIG. 2, the roll-shaped arrangement 200 may be formed by a mesh sheet 100 and may be provided by rolling up the mesh sheet 100.

FIG. 3 generally illustrates an example embodiment of a muffler 300 having a mesh sheet disposed therein. In some implementations, the mesh sheet 100 may be provided to the muffler in the roll-shaped arrangement 200 depicted in FIG. 2. One or more roll-shaped arrangements 200 may be incorporated within the muffler 300. It will be understood that the mesh sheet 100, possibly in the roll-shaped arrangement 200, may be incorporated elsewhere in an exhaust system, for example, in exhaust pipes. The mesh sheet 100 may reduce CO2 emissions; collect air impurities coming from engines smoke, and fuels; and improve engine and fuel efficiency. It will be further understood that the mesh sheet 100, possibly in the roll-shaped arrangement 200, may be incorporated into any number of similar air- or exhaust-related applications, for example, smoke stacks, chimneys, energy or manufacturing plants, air cleaners, air handlers, and air purifiers.

FIG. 4 generally illustrates an example embodiment of a wall container 400 having a mesh sheet analogous to the mesh sheet 100 disposed therein. In some implementations, the mesh sheet 100 may be provided behind a surface of the wall container 400. The mesh sheet 100 may act as a fire retardant or fire inhibitor for not allowing fire to cross walls, for example, not allowing fire to cross into one room or office from another.

FIG. 5a generally illustrates an example embodiment of a computer 500 having mesh sheet 100 disposed therein. In some implementations, the mesh sheet 100 may be provided beneath a surface of the computer. The mesh sheet 100 may act as a heat sink to reduce temperature at or near an area where high temperatures are generated.

FIG. 5b generally illustrates an example embodiment of a server 501 having mesh sheet 100 disposed therein. In some implementations, the mesh sheet 100 may be provided within a wall or ceiling of the server, as depicted in FIG. 5a. Additionally or alternatively, the mesh sheet 100 may be provided between racks. The mesh sheet 100 may act as a heat sink to reduce temperature at or near an area where high temperatures are generated.

It will be further understood that the mesh sheet 100, possibly in the roll-shaped arrangement 200, may be incorporated into any number of similar electronic applications, for example, electronic apparatuses, switches, electrical boxes, and appliances.

FIG. 6 generally illustrates another exemplary embodiment of a mesh roll 104. So as to maintain roll 104 in a rolled-up configuration, at least one containment ring 132 may be placed around the exterior of roll 104, as shown in FIG. 6. Ring 132 may be made from the same alloy as mesh sheet 100, may be formed from mesh sheet 100 itself, or may be formed from any other material. For example, ring 132 may be formed from a strip of mesh sheet 100 having a width of about 1-2 cm and a length substantially similar to the circumference of roll 134. The transverse edges of the strip may be welded to each other so as to form a ring 132 having a circumference substantially similar to the circumference of roll 134. Ring 132 may maintain roll 104 in a substantially cylindrical configuration, and reducing the likelihood of roll 104 being unrolled during transport, handling, and use. Ring 132 may further be removed after insertion of roll 104 into a container 106, as will be discussed in greater detail below.

FIG. 7 generally illustrates an exemplary embodiment of a container 106 having a mesh roll 104 disposed therein. At least one mesh roll 104 may be inserted into the container 106. The container 106 may be any desired container wherein a combustible liquid may be stored. As non-limiting examples, the types of containers 106 that may be contemplated include containers for the provision of fuel to a vehicle, such as ground vehicle fuel tanks, aircraft fuel tanks, marine vessel fuel tanks, and so forth. Further types of containers 106 that may be contemplated include containers for the storage of combustible liquids, such as tanker truck tanks, cargo train tanks, tanker vessel tanks, fixed fuel storage tanks, tank farms, LNG/LPG terminals, mobile fuel tanks and drums, and so forth. As an illustrative example, FIG. 7 shows that the container 106 may be a 55-gallon drum.

Liquids stored in the containers 106 depicted in FIGS. 7-11 may include any type of combustible or volatile liquids, for example, but not limited to, gasoline, jet fuel, diesel, propane, liquefied natural gas, liquefied petroleum gas, and so forth. The mesh sheet 100 may be used to reduce fire and explosion risk.

FIG. 8 generally illustrates an exemplary container wherein the container 106 is a fuel tank. As an illustrative example, FIG. 8 shows that the container 106 may be adapted to fit to a Humvee.

FIG. 9 generally illustrates an exemplary container wherein the container 106 is a jerry can.

FIG. 10 generally illustrates an exemplary container wherein the container 106 is a tanker trailer.

FIG. 11 generally illustrates an exemplary container wherein the container 106 is a fuel tank of a watercraft. In other implementations, the mesh sheet 100 may be incorporated into a bilge or storage tank. In this scenario, the mesh sheet 100 may act as a dampener to keep the center of mass in a stable state.

The mesh sheet 100 may also be used in aerospace applications. For example, the mesh sheet 100 may replace carbon fiber core material layers and external de-icing mechanisms, while reducing the weight and flammability of the craft.

Although FIGS. 2-11 depict several possible arrangements of the mesh sheet 100 and several possible systems or devices that may be fabricated so as to include the mesh sheet 100. However, it will be understood that the arrangements, systems, and devices depicted in FIGS. 2-11 is not limiting and that other arrangements, systems, and devices are possible. For example, the mesh sheet 100 may be used as an abrasive, as an electrical circuit, as a heating element, as an inline mixing hardware component, as a structural layer, as a de-icing component, as a static precipitations component, as an industrial fluids systems cleaning component, as a filtering element, or as a surface material for traction.

Mesh rolls 104 may be disposed within container 106 such that mesh rolls 104 substantially occupy the internal space of the container 106. For example, the space occupied by a mesh roll or rolls 104 may be substantially equal to the volume of the container, or may be approximately the maximum possible space that may be occupied. If multiple mesh rolls 104 are disposed within a container 106, the rolls may be close-packed within container 106 such that the space occupied by mesh rolls 104 is maximized and the interstitial space between mesh rolls 104 is minimized. This can facilitate the plurality of rolls 104 behaving as one body and reduce the likelihood of friction between the rolls 104. Such an arrangement is shown in FIGS. 4 and 5. Furthermore, rolls 104 may be deformed to facilitate fitting rolls 104 into an irregularly shaped container 106, as shown in FIG. 5. As used herein, the “space occupied” by any roll 104 can be substantially equal to the external dimensions of the particular roll 104 (for example, the product of the height and the diameter of a regularly-shaped cylindrical roll). In contrast, the “volume displaced” by any roll 104 can be substantially equal to the amount of liquid displaced by the particular roll 104.

While mesh rolls 104 may be disposed to occupy approximately the entire space within a container 106, the volume of liquid displaced by mesh rolls 104 may be no greater than approximately 2% of the total volume of container 104. In some exemplary embodiments, the volume of liquid displaced by mesh rolls 104 may be no greater than approximately 1.6% of the total volume of container 106. Therefore, while mesh rolls 104 may be close-packed so as to substantially occupy the maximum possible space within a container 106, the effect of mesh rolls 104 on the holding capacity of the container can such that the volume displaced by the rolls may be less than 2% of the total useable capacity of the container.

Furthermore, a container 106 having mesh rolls 104 disposed inside as described herein, can facilitate reducing evaporative loss of volatile liquids from the container. In some exemplary embodiments, a container 106 having mesh rolls 104 disposed therein may reduce evaporative losses of volatile liquids by over 50% compared to a container having the same configuration but without mesh rolls therein. The evaporative loss reduction can be accomplished by mesh rolls 104 reducing the temperature of the liquid disposed within container 106. Consequently, the use of mesh rolls 104 within a container 106 can provide for savings of fuel, as well as reduction of hydrocarbon emissions due to decreased evaporative loss.

It should also be appreciated that, as detached mesh particles may clog fuel lines or other conduits in communication with container 106, the protective edge plate 128 coupled to at least one edge of the mesh roll 104, can facilitate preventing such detachment, thereby reducing the necessity of maintenance of containers 106.

Additionally, the material of mesh sheet 100 can act as a sacrificial anode when mesh sheet 100 or mesh rolls 104 are disposed within a container 106 and immersed in liquid. The material of mesh sheet 100 can have anodic properties in relation to most known metallic materials used for construction of fuel storage containers, due to the material of mesh sheet 100 having an anodic index within the range of approximately 0.70-0.90 volts. Therefore, mesh rolls 100 disposed inside a container 106 can reduce the likelihood of corrosion of the container itself, thereby prolonging the effective life of the container.

As an example, some embodiments may include advanced air filters and oil filters incorporating the mesh sheet 100 (e.g., for cars, trucks, motorcycles, boats, trains, heavy machinery, etc.). These advanced air and oil filters may provide advantages in terms of reducing CO2 emissions; cooling temperatures going into the engine; collecting air impurities coming from the engine, smoke, and fuels; and improving engine and fuel efficiency.

As another example, some embodiments may include advanced exhaust pipes/mufflers incorporating the mesh sheet 100 (e.g., for cars, trucks, motorcycles, heavy machinery, etc.). These advanced exhaust pipes/mufflers may provide advantages in terms of reducing CO2 emissions; collecting air impurities coming from engines, smoke, and fuels; and improving engine and fuel efficiency.

As another example, some embodiments may include advanced air filtration systems and scrubbers incorporating the mesh sheet 100 for CO2 reduction (e.g., smoke stacks, air cleaners, air handlers, air purification, etc.). These advanced smokestacks may provide advantages in terms of reducing CO2 emissions; collecting air impurities coming from engines, smoke, and fuels; and improving engine and fuel efficiency.

As another example, some embodiments may include advanced building materials incorporating the mesh sheet 100 (e.g., inside walls or other materials). These advanced building materials may provide advantages in terms of acting as a fire retardant and inhibitor for not allowing fires to travel between walls or from one room/office to another.

As another example, some embodiments may include advanced IT equipment and other machinery generating heat incorporating the mesh sheet 100 (e.g., as a heat sink or the like). These advanced IT equipment and other equipment or machinery which generate or emit heat may provide advantages in terms of reducing temperatures near or in the area where high heat temperatures are generated by such equipment or machinery.

As another example, some embodiments may include advanced electric apparatus, switches, boxes and appliances incorporating the mesh sheet 100. These advanced electric apparatus and appliances which generate or emit heat may provide advantages in terms of reducing temperatures inside such appliances.

The following are examples of test results associated with various uses of mesh rolls 104.

In a first example, ballistic tests were performed on a 55-gallon drum containing combustible liquid and a roll of aluminum mesh substantially as described herein, and a control 55-gallon drum containing solely combustible liquid. Ballistic tests were performed using: 1) 7.62 mm M62 tracer round; 2) .50 caliber M20 armor piercing incendiary tracer round; and 3) .50 caliber M8 armor piercing incendiary round.

Ballistic test 1: 7.62 mm M62 tracer round, control 55-gallon drum. Result: explosive event. The round passed through the drum, with the drum bulging immediately thereafter. The drum subsequently elevated and gases began venting through the holes left by the bullet, indicating an explosive event. The drum came to rest on its side, leaking fuel, with the bottom and top panels of the drum deformed.

Ballistic test 2: 7.62 mm M62 tracer round, 55-gallon drum with mesh roll therein. Result: no explosive event. The round passed through the drum with no noticeable indication of deformation of the drum, nor any noticeable indication of combustion.

Ballistic test 3: .50 caliber M20 armor piercing incendiary tracer round, control 55-gallon drum. Result: explosive event. The round passed through the drum, with the drum bulging immediately thereafter. The drum subsequently elevated and gases began venting through the holes left by the bullet, indicating an explosive event. The drum came to rest upside-down, wedged between an impact plate and the side of a burn pan. The bottom and top panels of the drum were deformed.

Ballistic test 4: .50 caliber M20 armor piercing incendiary tracer round, 55-gallon drum with mesh roll therein. Result: no explosive event. The round passed through the drum with no noticeable indication of deformation of the drum, nor any noticeable indication of fire. Smoke was seen; however it was concluded that the smoke was the result of the burning tracer round and not from an explosive event inside the drum.

Ballistic test 5: .50 caliber M8 armor piercing incendiary round, control 55-gallon drum. Result: explosive event. The round passed through the drum, with the drum bulging immediately thereafter. The drum subsequently elevated and gases began venting through the holes left by the bullet, indicating an explosive event. The drum came to rest outside the burn pan, leaking fuel. Both the bottom and top panels of the drum were deformed.

Ballistic test 6: .50 caliber M20 armor piercing incendiary tracer round, 55-gallon drum with mesh roll therein. Result: no explosive event. The round passed through the drum with no noticeable indication of deformation of the drum. A flame was briefly seen exiting the front impact hole; however, the flame extinguished shortly thereafter. Smoke was seen; however it was concluded that the smoke was the result of the burning incendiary round and not from an explosive event inside the drum.

In a second example of test results associated with various uses of mesh rolls 104, leaking 55-gallon drums were exposed to fires stared near, but not inside the drum. The drums used were previously impacted with a bullet, or had similar holes cut in the sidewalls, which were plugged with stoppers. The external fire tests were performed on a 55-gallon drum containing JP-8 fuel and a roll of aluminum mesh substantially as described herein, and a control 55-gallon drum containing solely JP-8 fuel.

External fire test 1: 55-gallon drum with mesh roll therein, 7.62 mm hole. Result: no explosive event. A fire was started in a corner of the burn pan and slowly moved towards the drum. After the fire reached the drum, flames were observed occasionally shooting out of an open bunghole of the drum. Subsequent to burn completion, the drum was charred by the flames, but no deformation was observed.

External fire test 2: control 55-gallon drum, 19.05 mm hole. Result: explosive event. The drum burst into flames approximately 2-2.5 minutes after commencing the burn. The drum was observed as enlarging immediately prior to drum explosion. The seam between the top and side of the drum split due to internal pressure in the drum. Thermocouple readings indicated that a temperature of over 1800° F. was reached within the drum.

In a third example of test results associated with various uses of mesh rolls 104, welding operations using a remote welding device were performed on a 55-gallon drum containing 10 gallons of JP-8 fuel and a roll of aluminum mesh substantially as described herein. A vertical cut approximately 10 cm long and 1.9 cm wide was made approximately 6.35 cm from the top of the drum. Both bungholes were closed for this test.

Welding operations test 1: 55-gallon drum with mesh roll therein. Result: no explosive event. Shielded metal arc welding was performed using a 3/32 inch electrode at 125 amps. The amperage was elevated to simulate a worst-case potential, to ensure that the arc would be sustained, and so that the arc would pierce the drum. The arc was sustained for approximately 17 seconds, without yielding any significant flames, fire, or explosion. The hole penetrated approximately 3.81 cm of the mesh roll.

In a fourth example of test results associated with various uses of mesh rolls 104, fuel tanks were exposed to a thermite grenade which was placed on the top surface of the tank and allowed to burn through the tank. The thermite grenade tests were performed on a fuel tank containing diesel fuel and a roll of aluminum mesh substantially as described herein, and a control fuel tank containing solely diesel fuel.

Thermite grenade test 1: control fuel tank. Result: combustion and spreading of fuel. A thermite grenade was allowed to burn through a fuel tank and drop into the diesel fuel contained therein. Significant combustion was observed as the thermite grenade was inside the fuel tank. After the grenade burned through the bottom surface of the fuel tank, burning diesel fuel spread over a significant ground area, presenting difficulties for a firefighting crew to contain or extinguish the flames with a fire truck. The hot diesel burned until the fuel was exhausted.

Thermite grenade test 2: fuel tank with mesh roll therein. A thermite grenade was allowed to burn through a fuel tank and drop into the diesel fuel contained therein. A small fire was observed on top of the fuel tank. There was no observed spread of the flames beyond the small fire. The small fire was subsequently quickly extinguished by the firefighting crew with minimal water and effort.

Embodiments of mesh sheet 100, mesh rolls 104, and containers 106 having mesh rolls therein can therefore facilitate increasing the safety of combustible liquid storage and transport, provide environmental benefits by way of reduced evaporation of such liquids, and decrease the costs associated with combustible fuel storage and transport. Furthermore, such embodiments can increase the safety in military applications, whereby containers such as fuel tanks may be provided with mesh rolls 104, thereby significantly decreasing the likelihood of severe detonation as a consequence of ordnance impacts.

FIGS. 12a-12d generally illustrate an exemplary embodiment of a UR-RR machine 200. FIG. 12a generally illustrates a perspective view, FIG. 12b generally illustrates a side view, FIG. 12c generally illustrates an end view, and FIG. 12d generally illustrates a top view. In each of FIG. 12a-12d, a direction of a longitudinal dimension is marked with a solid arrow, a direction of a transverse dimension is marked with a dashed arrow, and a direction of a vertical dimension is marked with a dotted arrow. A measurement across the longitudinal dimension may be referred to as a length, a measurement across the transverse dimension may be referred to as a width, and a measurement across the vertical dimension may be referred to as a height and/or thickness.

A desired quantity of the manufactured expanded metal mesh sheet 100 may be wound into a first mesh roll 102. In some exemplary embodiments, the first mesh roll may have a diameter of, for example, greater than 60 cm. The first mesh roll 102 can then be utilized with an exemplary embodiment of the unreeling—rereeling (UR-RR) machine 200. UR-RR machine 200 can generate at least one second mesh roll 104 from the first mesh roll 102. The diameter of the second mesh roll 104 can be adjusted as desired depending on the size and configuration of the particular container in which rolls 104 may be disposed. Furthermore, at least one transverse edge 124, or both transverse edges 124, 126, of the second mesh roll 104 may be treated so as to reduce the likelihood of fraying, deterioration, or disintegration of the mesh proximate the edge.

Machine 200 can include a frame 202 for supporting the components thereof. An unreeling shaft 204 coupled to frame 202 may rotatably support a first mesh roll 102 thereon. As the first mesh roll 102 is unrolled, the expanded metal mesh sheet 100 can be engaged by a plurality of rollers 206. Rollers 206 may be coupled to frame 202 and disposed substantially horizontally, so as to facilitate maintaining mesh sheet 100 stretched and substantially horizontal. A reeling shaft 208 rotatably coupled to frame 202 can support a second mesh roll 104 thereon. Reeling shaft 208 may be powered by motor 210 and operatively coupled thereto, for example by a belt or chain 209. Motor 210 may be an electric motor, or may be any other motor known in the art. Disposed between rollers 206 and reeling shaft 208 may be an edge treatment unit 212. The edge treatment unit 212 can include a base plate 216, a movable engagement plate 218, a cutting device 224 and a welding device 226. A channel 217 may be defined between the base plate 216 and the engagement plate 218 for passage of mesh sheet 100 therethrough. A roller 220 may be positioned after plates 216, 218 and before reeling shaft 208. Roller 220 may be coupled to frame 202 and disposed substantially horizontally, so as to facilitate maintaining mesh sheet 100 stretched and substantially horizontal.

The expanded metal mesh sheet 100 unrolled from first mesh roll 102 may be passed through rollers 106, between plates 216, 218 of edge treatment unit 212, over roller 220, and then coupled to reeling shaft 208 by a first edge 124 of the mesh sheet 100. Upon rotation of reeling shaft 208, the mesh sheet 100 may be unwound from first roll 102, drawn through rollers 106 through edge treatment unit 212, and over roller 220. The second roll 104 can thus be generated. The mesh sheet 100 may be wound onto second roll 104 until a desired diameter of second roll 104 is achieved.

A control panel 214 may control the operation of machine 200, including motor 210 and edge treatment unit 212. To that end, control panel 214 may be communicatively coupled to motor 210 and edge treatment unit 212. In some exemplary embodiments, control panel 214 may further include a user-operable interface for entry of desired specifications, such as, for example, the desired diameter of second roll 104, or the desired length of mesh sheet 100 to be included in second roll 104.

Edge treatment unit 212 can be operable to cut mesh sheet 100 so as to create a second transverse edge 126 of the mesh sheet 100 of second roll 104. The cutting operation can also create a new first transverse edge 124 of the mesh sheet 100 of first roll 104. The edge treatment unit 212 can further treat the second transverse edge 126 so as to reduce the likelihood of fraying, deterioration, or disintegration of the edge. The cutting operation may be performed, for example, when a desired diameter for second roll 104 is achieved, and when the operation of reeling shaft 208 is stopped.

FIGS. 13a-13b show a detail of the edge treatment unit 212 depicted in FIG. 12a-12d. FIG. 13a generally illustrates a perspective view and FIG. 13b generally illustrates a top view.

Edge treatment unit 212 can include a base plate 216, an engagement plate 218, and a cutting device 224. Engagement plate 218 may be movable in a vertical direction as well as a direction parallel to the longitudinal axis of mesh sheet 100. Engagement plate 218 can further include a plurality of protruding members 222 extending downwardly therefrom, which can facilitate engaging mesh sheet 100. The protruding members 222 may engage the edges of apertures 110 of mesh sheet 100.

Cutting device 224 may include a slit 225 wherein at least one blade may be disposed, the blade being capable of cutting through mesh sheet 100. Cutting device 224 may mounted so as to be laterally movable in a direction perpendicular to the longitudinal axis of mesh sheet 100.

Prior to the cutting operation, control panel 214 may stop the operation of reeling roll 108 such that the intended location of second transverse edge 126 of second roll 104 is positioned substantially proximate cutting device 224. The intended location of the second transverse edge 126 of roll 104 may be determined by control panel 214 such that, when sheet 100 is subsequently fully rolled onto roll 104, the desired diameter of roll 104 may be achieved. Cutting of the mesh sheet 100 may subsequently be performed by cutting device 224 in cooperation with engagement plate 218.

To execute the cutting operation, cutting device may move into an operating position so as to dispose mesh sheet 100 within slit 225 such that the mesh may be cut by the at least one blade. Substantially simultaneously, engagement plate 218 can move in a vertical direction so as to engage sheet 100 with protruding members 222. Subsequently, the cutting device may move into a resting position such that cutting device 224 does not interfere with the further operation of edge treatment unit 212, while mesh sheet 100 may be held in place by base plate 216 and engagement plate 218. A new second transverse edge 126 of roll 104 can thus be generated.

Edge treatment unit 212 may further be operable to treat the second transverse edge 126 of roll 104 so as to protect the edge from fraying and deterioration. This may be accomplished by providing a protective edge plate 128 and coupling the plate to transverse edge 126, for example by welding. To that end, edge treatment unit 212 may further include a welding device 226, which may be an ultrasonic welding device or any other welding device that enables UR-RR machine 200 to function as described herein. Welding device 226 can further include a welding sonotrode or horn 230 which can contact an anvil 232.

Edge treatment unit 212 may further include a plurality of protective plate delivery arms 228. Each delivery arm 228 may include a head 229 slidably coupled to the delivery arm. In some exemplary embodiments, the delivery arms 228 can include at least two outer delivery arms 228a and at least one inner delivery arm 228b. Delivery arms 228 may be pivotably mounted on UR-RR machine 200 such that the arms 228 may pivot about the transverse dimension. However, any other protective plate delivery device that enables machine 200 to function as described herein may be contemplated and provided as desired.

FIGS. 15a-15d generally illustrate an exemplary embodiment of a protective plate. FIG. 15a generally illustrates a perspective view, FIG. 15b generally illustrates a side view, FIG. 15c generally illustrates another side view, and FIG. 12d generally illustrates yet another top view.

Protective edge plate 128 may have a width substantially similar to the width of mesh sheet 100. The length of protective edge plate 128 may be less than the width thereof, and may be any length that enables UR-RR machine 200 to function as described herein. In some exemplary embodiments, protective edge plate 128 may have an angular configuration. To that end, protective edge plate 128 can have a crease extending substantially parallel to the major axis thereof. The edges of protective edge plate 128 that are parallel to the crease may be folded about the crease so as to form a pair of arms 130 having an angle of less than 180° therebetween, as shown in FIG. 15a-15b. Protective edge plate 128 may be detachably coupled to heads 229 of delivery arms 228. In other exemplary embodiments, as shown in FIG. 15d, a lower protective edge plate 128a and an upper protective edge plate 128b may be provided and coupled to transverse edge 126 in a sandwich formation.

To execute the edge treatment operation, engagement plate 218, still being engaged with mesh sheet 100, may translate in the direction of first roll 102 so as to position second transverse edge 126 of roll 104 between horn 230 and anvil 232, as shown in FIG. 14b. Delivery arms 228 may then pivot towards anvil 232 so as to position protective edge plate 128 in proximity, and substantially parallel to, to transverse edge 126. Subsequently, heads 229 of delivery arms 228 may extend so as to translate in the direction of second roll 104, thereby disposing transverse edge 126 between the arms 130 of, and substantially proximate the vertex of, protective edge plate 128. The protective edge plate 128 is therefore also positioned between horn 230 and anvil 232.

In some exemplary embodiments, at this point, inner delivery arms 228b may retract to the original position (shown in dotted lines in FIG. 14b). Outer delivery arms 228a, however, may not yet retract, and may press protective edge plate 128 against anvil 232 so as to provide stability for protective edge plate 128 during the welding operation. Subsequently, horn 230 may weld protective edge plate 128 to transverse edge 126 of roll 104. In some exemplary embodiments, transverse edge 126 may be disposed between arms 130 of protective edge plate 128, and welded thereto, as shown in FIG. 15b-15c.

In some exemplary embodiments, horn 230 and/or welding device 226 may translate along the transverse axis of protective edge plate 128 to execute the welding operation. In such embodiments, the protective edge plate 128 may be subdivided into a plurality of welding portions or strips having a length corresponding to the width of horn 230. For example, in some embodiments, protective plate 228 may have a width of approximately 24 cm, while horn 230 may have a width of approximately 6 cm. In such embodiments, protective edge plate 128 may be provided with four welding portions or strips, each welding strip having a length of 6 cm.

In some exemplary embodiments, during the welding operation, horn 230 may first weld the inner portions of protective edge plate 128. Subsequently, outer delivery arms 228a may retract into the original position, so as to provide clearance for horn 230 to weld the outer portions of protective edge plate 128.

Subsequent to the edge treatment operation, reeling shaft 208 may rotate so as to wind the remainder of sheet 100 onto second roll 104. Second roll 104 may then be removed from UR-RR machine 200. If desired, the new first edge 124 of first roll 102 may then be passed through edge treatment unit 212, over roller 220, and coupled to reeling shaft 208, in preparation for further operation.

As second transverse edge 126 is disposed on the exterior of roll 104, the above-described treatment of second transverse edge 126 can increase the durability of roll 104 during handing, such that friction with adjacent objects, adjacent rolls, or with the walls of a container wherein the roll is disposed does not result in fraying, progressive deterioration, and disintegration of the mesh through detachment of mesh particles from mesh sheet 100. As the first transverse edge 124 is disposed in the interior of roll 104, the likelihood of deterioration of first transverse edge 124 due to handling and friction may be less than that of second transverse edge 126, or may be completely reduced due to a lack of friction. Therefore, the embodiment of UR-RR machine 200 described above is adapted to treat solely the second transverse edge 126 of roll 104. However, in other exemplary embodiments, the UR-RR machine 200 may be adapted to additionally treat the first transverse edge 124. To that end, an additional welding device and delivery arms may be provided. The additional welding device and delivery arms may be positioned, oriented and configured so as to treat the first transverse edge 124 of first roll 102 prior to coupling edge 124 to reeling shaft 108. The specific positioning, orientation and configuration of the additional welding device and delivery arms may be appreciated by one having ordinary skill in the art.

The terminology used herein is for the purpose of describing particular embodiments only and not to limit any embodiments disclosed herein. As used herein, the singular forms “a”, “an” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms “comprises”, “comprising”, “includes” and/or “including”, when used herein, specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof. Similarly, the phrase “based on” as used herein does not necessarily preclude influence of other factors and should be interpreted in all cases as “based at least in part on” rather than, for example, “based solely on”.

It will be understood that terms such as “top” and “bottom”, “left” and “right”, “vertical” and “horizontal”, “longitudinal” and “transverse”, etc., are relative terms used strictly in relation to one another, and do not express or imply any relation with respect to gravity, a manufacturing device used to manufacture the components described herein, or to some other device to which the components described herein are coupled, mounted, etc. To describe the locations in physical space of various objects and components, the present application may refer to orthogonal dimensions in three-dimensional space, axes that coincide with the orthogonal dimensions, and rotation around or movement in a direction of a particular axis.

It will be understood that any reference to an element herein using a designation such as “first,” “second,” and so forth does not generally limit the quantity or order of those elements. Rather, these designations may be used herein as a convenient method of distinguishing between two or more elements or instances of an element. Thus, a reference to first and second elements does not imply that there are only two elements and further does not imply that the first element must precede the second element in some manner. Also, unless stated otherwise a set of elements may comprise one or more elements. In addition, terminology of the form “at least one of A, B, or C” or “one or more of A, B, or C” or “at least one of the group consisting of A, B, and C” used in the description or the claims means “A or B or C or any combination of these elements.”

While the foregoing disclosure shows various illustrative aspects, it should be noted that various changes and modifications may be made to the illustrated examples without departing from the scope defined by the appended claims. The present disclosure is not intended to be limited to the specifically illustrated examples alone. For example, unless otherwise noted, the functions, steps, and/or actions of the method claims in accordance with the aspects of the disclosure described herein need not be performed in any particular order. Furthermore, although certain aspects may be described or claimed in the singular, the plural is contemplated unless limitation to the singular is explicitly stated.

Claims

1. An apparatus for manufacturing a second mesh roll from a first mesh roll, the apparatus comprising: an unreeling shaft configured to rotatably support the first mesh roll and provide an unreeled length of the first mesh roll in a longitudinal direction;an edge treatment unit configured to: receive the unreeled length of the first mesh roll; andcut the first mesh roll along a transverse axis and treat one or more edges of the first mesh roll to form the second mesh roll; anda reeling shaft configured to receive and rotatably support the second mesh roll.

2. The apparatus of claim 1, further comprising: at least one motor configured to: rotate the unreeling shaft in order to provide the unreeled length of the first mesh roll; and/orrotate the reeling shaft in order to receive and rotatably support the second mesh roll.

3. The apparatus of claim 1, further comprising rollers configured to deliver the unreeled length of the first mesh roll to the edge treatment unit.

4. The apparatus of claim 1, wherein the edge treatment unit comprises: a base plate; andan engagement plate configured to operate in tandem with the base plate to selectively hold in place the first mesh roll.

5. The apparatus of claim 1, wherein the edge treatment unit comprises: a cutting device having a slit with a blade disposed therein, wherein the cutting device is configured to selectively cut the first mesh roll along a transverse axis to create a transverse edge.

6. The apparatus of claim 1, wherein the edge treatment unit comprises: a welding device configured to weld at least one protective edge plate to the transverse edge and/or an area adjacent thereto.

7. The apparatus of claim 6, wherein the at least one protective edge plate has the same width as the transverse edge.

8. The apparatus of claim 6, wherein the at least one protective edge plate comprises a first arm, a second arm, and a crease separating the first arm and the second arm and extending in the transverse dimension, wherein the at least one protective edge plate is formed by folding the at least one protective edge plate along the crease.

9. The apparatus of claim 8, wherein to weld the at least one protective edge plate to the transverse edge, the welding device is further configured to: weld the first arm of the at least one protective edge plate to a top of the first mesh roll; andweld the second arm of the at least one protective edge plate to a bottom of the first mesh roll;wherein the crease is disposed around the transverse edge and the at least one protective edge plate is configured to protect the transverse edge from fraying, progressive deterioration, edge disintegration, or any combination thereof.

10. The apparatus of claim 6, wherein the at least one protective edge plate comprises an upper protective edge plate and a lower protective edge plate.

11. The apparatus of claim 10, wherein to weld the at least one protective edge plate to the transverse edge, the welding device is further configured to: weld the upper protective edge plate to a top of the first mesh roll; andweld the lower protective edge plate to a bottom of the first mesh roll;wherein the upper protective edge plate and the lower protective edge plate are disposed adjacent to the transverse edge and are configured to protect the transverse edge from fraying, progressive deterioration, edge disintegration, or any combination thereof.

12. The apparatus of claim 6, wherein the welding device comprises: a horn configured to translate along a transverse axis; andan anvil;wherein the horn and anvil are configured to accommodate the transverse edge and weld the at least one protective edge plate to the transverse edge and/or an area adjacent thereto.

13. The apparatus of claim 6, further comprising: at least one protective plate delivery arm configured to position the at least one protective edge plate with respect to the transverse edge.

14. The apparatus of claim 1, further comprising a control panel configured to selectively perform one or more of the following: command the unreeling shaft to rotate in order to provide the unreeled length of the first mesh roll;command the reeling shaft to rotate in order to receive and rotatably support the second mesh roll;command an engagement plate to hold in place and/or release the first mesh roll;command a cutting device to selectively cut the first mesh roll along a transverse axis to create a transverse edge;command at least one protective plate delivery arm to position at least one protective edge plate with respect to the transverse edge; and/orcommand a welding device to weld the at least one protective edge plate to a transverse edge of the first mesh roll and/or an area adjacent thereto.

15. The apparatus of claim 1, where the edge treatment unit is further configured to crimp one or more longitudinal edges of the first mesh roll.

16. The apparatus of claim 1, wherein the second mesh roll comprises: a plurality of strips; anda plurality of apertures formed between the plurality of strips.

17. The apparatus of claim 1, wherein the second mesh roll comprises an aluminum alloy comprising: aluminum; andone or more of silicon (Si), iron (Fe), copper (Cu), manganese (Mn), magnesium (Mg), chromium (Cr), and zinc (Zn).

18. A method of manufacturing a second mesh roll from a first mesh roll, the method comprising: rotatably supporting the first mesh roll on an unreeling shaft and providing an unreeled length of the first mesh roll in a longitudinal direction;receiving the unreeled length of the first mesh roll in an edge treatment unit;cutting the first mesh roll along a transverse axis and treating one or more edges of the first mesh roll to form a second mesh roll;receiving and rotatably supporting the second mesh roll on a reeling shaft.

19. The method of claim 18, further comprising: selectively cutting the first mesh roll along a transverse axis to create a transverse edge; andwelding at least one protective edge plate to the transverse edge and/or an area adjacent thereto, wherein the at least one protective edge plate has the same width as the transverse edge.

20. The method of claim 18, further comprising: crimping one or more longitudinal edges of the first mesh roll.