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US 2003/0188415 A1Published application
Apparatus and method of making a continuous laminate coil
AssigneeGKD-USA Incorporated
InventorsRick Thomas Kenney, Todd Kenneth Fischer
Life of this patent
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Abstract
A method and an apparatus incorporating the method for making a long, continuous laminate. A plurality of layers of materials are simultaneously wound around a metal hub. Strips of refractory material, perforated metal, metal foil, metal mesh, and random fiber media, are employed in the layers of materials. The hub, once completed, is placed into a furnace for diffusion bonding and later cooled to room temperature. The cooled laminate coil may be cut into various lengths.
Claims28
A method for making a continuous laminate coil, said method comprising:
- providing a rewinder drum to receive a plurality of layers of materials wound around its circumference;
- winding, simultaneously into layers around the circumference of said rewinder drum, a refractory material strip, a metal strip, and at least one metal mesh strip;
- maintaining tension on said refractory material, said metal strip, and at least one metal mesh strips thereby building a contact pressure between the layers while forming a take-up reel around said rewinder drum;
- securing loose end of said wound metal strip to said take-up reel to maintain tension and contact pressure between the layers;
- diffusion bonding said take-up reel in a furnace to form a laminate coil;
- and
- cooling said laminate coil to room temperature.
4 more elements
A method for making a continuous laminate coil, said method comprising:
- providing a rewinder drum to receive a plurality of layers of materials wound around its circumference;
- winding, simultaneously into layers around the circumference of said rewinder drum, a refractory material strip, a perforated metal strip, and at least one metal mesh strip;
- maintaining tension on said refractory material, said perforated metal, and at least one metal mesh strips thereby building a contact pressure between the layers while forming a take-up reel around said rewinder drum;
- securing loose ends of said wound refractory material, said perforated metal and at least one metal mesh strips to said take-up reel to maintain tension and contact pressure between the layers;
- diffusion bonding said take-up reel in a furnace to form a laminate coil;
- and
- cooling said laminate coil to room temperature.
4 more elements
A method for making a continuous laminate coil, said method comprising:
- providing a ceramic coated metal hub to receive a plurality of layers of material wound around its circumference;
- winding, simultaneously into layers around the circumference of said hub, a refractory material strip as a base, a perforated metal strip, and a first and a second metal mesh strips stacked on top of each other, respectively;
- aligning said plurality of layers of materials with an edge guide system;
- securing loose ends of said wound refractory material, said perforated metal and said first and second metal mesh strips to said wound coil to maintain tension and contact pressure between the layers;
- diffusion bonding said take-up reel in a furnace thus forming a laminate coil;
- and
- cooling said laminate coil to room temperature.
4 more elements
A continuous laminate coil apparatus, comprising:
- a rewinder drum adapted for receiving a plurality of layers of strip material wound around its circumference;
- said rewinder drum mounted to a rewinder, forming a take-up reel with wound layers of strip materials wound around the circumference of said rewinder drum;
- a refractory material core, including a refractory material strip which is wound around the circumference of said rewinder drum;
- a tension controlled uncoiler, including a metal strip which is wound around the circumference of said rewinder drum on top of said refractory material strip;
- a roll straightener for positioning and handling said metal strip as it exits said tension controlled uncoiler, insuring that said metal strip is flat;
- a first mesh core, including a first metal mesh strip which is wound around the circumference of said rewinder drum on top of said metal strip;
- a second mesh core, including a second metal mesh strip which is wound around the circumference of said rewinder drum on top of said first metal mesh strip;
- a third mesh core, including a third metal mesh strip which is wound around the circumference of said rewinder drum on top of said second metal mesh strip;
- a fourth mesh core, including a fourth metal mesh strip which is wound around the circumference of said rewinder drum on top of said third metal mesh strip;
- and
- an edge guide system, wherein a series of sensors are located to measure the position of said metal strip and said first through fourth metal mesh strips to properly align the strips in a stacking fashion before and during placement on top of said refractory material for simultaneous winding around the circumference of said rewinder drum, wherein sensors at predetermined locations juxtaposed to said rewinder monitor said plurality of layers of materials and adjust said rewinder if the plurality of layers of strip materials are misaligned as they are simultaneously wound around the circumference of said rewinder drum.
8 more elements
Dependencies are inferred from the claim text.