Milanese mesh rolling

Abstract

A flexible Milanese mesh material is disclosed herein. Particularly, the Milanese mesh material may have a structure that is conducive to a more flexible mesh material. The Milanese mesh may be formed from rows of wire spirals having a flexibility improving cross-section. The flexibility of the Milanese mesh may be improved by applying a secondary finishing process to the Milanese mesh. The finishing process may include continuously rolling the Milanese mesh around and/or against a mandrel such that the Milanese mesh product forms a smaller loop around the mandrel as the flexibility of the Milanese mesh product improves.

We claim: 
     
         1 . A mesh carpet comprising
 a first wire coil having a cross-section defined by a first surface and a second surface which oppose one another, with the first surface and the second surface connected by a transition surface; and   a second wire coil threaded into the first wire coil such that the first surface contacts a second wire coil surface; wherein   the first wire coil and the second wire coil form two rows of the mesh carpet.   
     
     
         2 . The mesh carpet of  claim 1 , wherein the first surface and the second surface are opposing flat surfaces positioned at an acute angle from one another. 
     
     
         3 . The mesh carpet of  claim 1 , wherein the first surface and the second surface are opposing flat surfaces positioned at an obtuse angle from one another. 
     
     
         4 . The mesh carpet of  claim 1 , wherein the first surface and the second surface are concave surfaces with the concave surfaces having a profile that approximately matches the second wire coil surface. 
     
     
         5 . The mesh carpet of  claim 1 , wherein:
 the first surface and the second surface are opposing flat surfaces positioned at an angle to one another; and   a first side of the first surface and a first side of the second surface are connected by a first arc that is a portion of the cross-section of the wire that is proximal to the coil axis.   
     
     
         6 . The mesh carpet of  claim 5 , wherein:
 the transition surface is an arc;   a second side of the first surface and a second side of the second surface are connected by a transition surface that is a second arc; and   the second arc is longer than the first arc.   
     
     
         7 . A method of forming a mesh carpet comprising:
 obtaining a first coiled wire having a cross-section defined by a first surface and a second surface which oppose one another, with the first surface and the second surface connected by a transition surface;   obtaining a second coiled wire;   
       intertwining the second wire into the first wire to form a mesh carpet; and 
       contacting the first surface with the second coiled wire. 
     
     
         8 . The method of  claim 7 , wherein the first surface and the second surface are opposing flat surfaces positioned at an angle to one another. 
     
     
         9 . The method of  claim 7 , wherein the first surface and the second surface are concave surfaces having a profile that approximately matches the second wire coil surface. 
     
     
         10 . The method of  claim 8 , wherein the operation of intertwining is accomplished by contacting the first surface with a first exterior convex surface of the second wire. 
     
     
         11 . The method of  claim 9 , wherein the operation of intertwining is accomplished by contacting the first concave surface with a first exterior convex surface of the second wire. 
     
     
         12 . The method of  claim 7 , further comprising obtaining a third wire and intertwining the third wire into the second wire. 
     
     
         13 . A method of improving the flexibility of a mesh carpet comprising:
 constraining a first end of the mesh carpet in a restraint;   constraining a second end of the mesh carpet in a movable restraint;   wrapping the mesh carpet around a first mandrel having a circumference smaller than natural mesh flexibility circumference; and   continuously moving the mesh carpet around the first mandrel, thereby forming a smaller mesh flexibility circumference without the mesh carpet being impacted by the first mandrel or additional mandrels.   
     
     
         14 . The method of  claim 13 , wherein, as the mesh carpet continuously moves around the first mandrel, the first mandrel rotates such that the mesh carpet and any points of contact between the mesh carpet and the first mandrel are substantially stationary relative to one another, thereby preventing the mesh carpet from sliding across the circumference of the first mandrel. 
     
     
         15 . The method of  claim 14 , further comprising:
 moving the first mandrel away from a first end of the mesh carpet that is in a fixed restraint until a substantial portion of the mesh carpet has moved around the first mandrel; and   moving the second end of the mesh carpet that is in a movable restraint in the opposite direction, thereby causing the first mandrel and the mesh carpet to move back around the first mandrel in the opposite direction until the first mandrel has returned to an original location.   
     
     
         16 . The method of  claim 15 , further comprising locating the mesh carpet between a first restraint plate and a second restraint plate as the mesh carpet is moved around the first mandrel. 
     
     
         17 . The method of  claim 16 , further comprising:
 contacting the mesh carpet with the first restraint plate; and   moving the first restraint plate closer to the second restraint plate after a substantial portion of the mesh carpet has moved around the first mandrel at least once, thereby causing the circumference of the mesh carpet to be compressed between the first restraint plate and the second restraint plate.   
     
     
         18 . The method of  claim 13 , further comprising moving the mesh carpet to a smaller mandrel after a substantial portion of the mesh carpet has moved around the first mandrel. 
     
     
         19 . The method of  claim 18  wherein as the mesh carpet continuously moves around the mandrel, the mandrel is stationary causing the mesh carpet to slide across the circumference of the mandrel. 
     
     
         20 . The method of  claim 13 , further comprising:
 wrapping the mesh carpet around a second mandrel and a third mandrel such that the mesh carpet occupies a zigzag pattern across the first mandrel, second mandrel, and third mandrel; and   driving the mesh carpet back and forth through the path of the first mandrel, second mandrel, and third mandrel.   
     
     
         21 . An apparatus for improving the flexibility of a mesh carpet, comprising:
 a first mandrel having a circumference smaller than natural mesh flexibility circumference;   a first restraint attached to the first end of the mesh carpet;   a second restraint attached to the second end of the mesh carpet and the second restraint is located relative to the first restraint such that the mesh carpet wraps around the first mandrel.   
     
     
         22 . The method of  claim 21 , wherein:
 the first mandrel rotates such that as the mesh carpet moves around the first mandrel the mesh carpet; and   all points of contact between the mesh carpet and the first mandrel are substantially stationary relative to one another, thereby limiting the mesh carpet from sliding across the circumference of the first mandrel.   
     
     
         23 . The method of  claim 22 , wherein:
 the first restraint is a fixed restraint;   the second restraint is a movable restraint;   the first mandrel is movable laterally such that, in response to the mandrel moving, the mesh carpet is pulled around the mandrel by a static force from the first restraint; and   the second restraint is configured to receive a force that moves the mesh carpet and the mandrel back to an original position.   
     
     
         24 . The method of  claim 23 , further comprising a first restraint plate and a second restraint plate, the mesh carpet and the first mandrel located between the first restraint plate and the second restraint plate. 
     
     
         25 . The method of  claim 23 , wherein:
 the first restraint plate contacts the mesh carpet and is configured to be movable relative to the second restraint plate, thereby allowing the gap between the first restraint plate and the second restraint plate to decrease as the circumference of the mesh carpet decreases.   
     
     
         27 . The method of  claim 21 , wherein the first mandrel is stationary causing the mesh carpet to slide across the circumference of the mandrel. 
     
     
         28 . The method of  claim 21 , further comprising a second mandrel and a third mandrel positioned relative to one another such that the mesh carpet forms a zigzag pattern as the mesh carpet is wrapped around the first mandrel, second mandrel, and third mandrel.