Apparatus and method for joining sheets of woven material

Abstract

Disclosed herein are an apparatus and method for joining sheets of woven material such as wire cloth in side-by-side relation to form a unitary sheet of material having a greater width. In accordance with one preferred embodiment, the apparatus includes a joining mechanism for joining the multiple sheets to form a unitary sheet, and optionally, either or both of a planarizing mechanism for reducing (or eliminating) differences in the thickness of the joint(s) from the bulk of the unitary sheet and a coating mechanism for coating at least areas of the unitary sheet near a joint. Following processing, the unitary sheet can be wound on a spindle to form a roll of woven material having greater than standard width.

What is claimed is:  
     
         1 . An apparatus for joining sheets of woven wire material side-by-side, said apparatus comprising: 
 a feeding and alignment mechanism that continuously feeds a plurality of sheets of woven wire material and aligns the plurality of sheets of woven wire material in side-by-side relation; and    a joining mechanism that joins the plurality of sheets of woven wire material side-by-side to form a unitary sheet of woven wire material.    
     
     
         2 . The apparatus of  claim 1 , and further comprising a support rack that supports a plurality of supply rolls of woven wire material from which the plurality of sheets are unwound.  
     
     
         3 . The apparatus of  claim 1 , and further comprising a spindle upon which said unitary sheet is wound.  
     
     
         4 . The apparatus of  claim 1 , wherein the joining mechanism comprises means for stitching the plurality of sheets together.  
     
     
         5 . The apparatus of  claim 1 , wherein the joining mechanism comprises means for stapling the plurality of sheets together.  
     
     
         6 . The apparatus of  claim 1 , wherein the joining mechanism comprises means for adhering the plurality of sheets together.  
     
     
         7 . The apparatus of  claim 1 , wherein the joining mechanism comprises means for welding the plurality of sheets together.  
     
     
         8 . The apparatus of  claim 1 , wherein each of said plurality of sheets includes warp wires and weft wires, wherein the joining mechanism comprises means for forming an interlocking joint in which weft wires of at least one of said plurality of sheets are hooked around at least one warp wire of another of said plurality of sheets.  
     
     
         9 . The apparatus of  claim 1 , and further comprising a coating mechanism that coats at least a portion of the unitary sheet with a corrosion-resistant coating.  
     
     
         10 . The apparatus of  claim 9 , wherein the coating mechanism comprises a sprayer.  
     
     
         11 . The apparatus of  claim 9 , wherein the coating mechanism comprises a bath through which the unitary sheet is drawn.  
     
     
         12 . The apparatus of  claim 1 , and further comprising a planarizing mechanism that planarizes the unitary sheet such that a thickness of the unitary sheet at a joint region is reduced.  
     
     
         13 . The apparatus of  claim 12 , wherein the planarizing mechanism comprises a plurality of opposed rollers.  
     
     
         14 . The apparatus of  claim 12 , wherein the planarizing mechanism reduces the thickness at the joint region to substantially an original thickness of one of said plurality of sheets.  
     
     
         15 . A method of joining sheets of woven wire material side-by-side, said method comprising: 
 continuously feeding a plurality of sheets of woven wire material and aligning the plurality of sheets of woven wire material in side-by-side relation; and    joining the plurality of sheets of woven wire material side-by-side to form a unitary sheet of woven wire material.    
     
     
         16 . The method of  claim 15 , and further comprising supporting a plurality of supply rolls of woven wire material utilizing a supply rack, wherein the plurality of sheets are fed from the plurality of supply rolls supported by the supply rack.  
     
     
         17 . The method of  claim 15 , and further comprising winding the unitary sheet about a spindle to form a receiving roll.  
     
     
         18 . The method of  claim 15 , wherein joining the plurality of sheets comprises stitching the plurality of sheets together.  
     
     
         19 . The method of  claim 15 , wherein joining the plurality of sheets comprises stapling the plurality of sheets together.  
     
     
         20 . The method of  claim 15 , wherein joining the plurality of sheets comprises adhering the plurality of sheets together.  
     
     
         21 . The method of  claim 15 , wherein joining the plurality of sheets comprises welding the plurality of sheets together.  
     
     
         22 . The method of  claim 15 , wherein each of said plurality of sheets includes warp wires and weft wires, wherein joining the plurality of sheets comprises forming an interlocking joint in which weft wires of at least one of said plurality of sheets are hooked around at least one warp wire of another of said plurality of sheets.  
     
     
         23 . The method of  claim 15 , and further comprising coating at least a portion of the unitary sheet with a corrosion-resistant coating.  
     
     
         24 . The method of  claim 23 , wherein coating comprises applying a spray coating.  
     
     
         25 . The method of  claim 23 , wherein coating comprises drawing said unitary sheet through a bath.  
     
     
         26 . The method of  claim 15 , and further comprising planarizing the unitary sheet such that a thickness of the unitary sheet at a joint region is reduced.  
     
     
         27 . The method of  claim 26 , wherein planarizing comprises planarizing utilizing a plurality of opposed rollers.  
     
     
         28 . The method of  claim 26 , wherein planarizing reduces a thickness at the joint region to substantially an original thickness of one of said plurality of sheets.