Improved reinforcement for a moulded filtering screen support frame

Abstract: A method is described for making a reinforcing wire frame for embedding in a moulded polymer support frame (10) over which woven wire cloth (158,159) is to be stretched and secured to form a sifting screen. The method involves locating lengths of cut wire (50) substantially equally spaced apart in a jig to form a first array. A second array of lengths of cut wire (56,60) is located over the first array with the lengths of wire in the second array being substantially at right angles to those of the first array. The lengths of wire in the first and second arrays are resistance welded at points of mutual intersection so as to form a first substantially rectilinear matrix. Lengths of cut wire (48) are located in a jig to form a third array, in which the lengths are also substantially equally spaced apart, and a fourth array of lengths of cut wire (54,58,62,64) is arranged over the third array with the lengths of the fourth array substantially at right angles to the lengths of wire of the third array, and the wires of the third and fourth arrays are also resistance welded at points of mutual intersection to form a second substantially rectilinear matrix. Protruding lengths of wire on at least two sides of the four sides of one of the rectilinear matrices are bent using a press so as to bend each protruding length first in a generally upward sense and then at a point nearer its end in a generally downward sense so that an end region of each protruding length extends parallel to a plane of the matrix but is displaced therefrom. Thereafter the displaced ends of the protruding lengths of wire of one matrix are resistance welded to protruding lengths of wire of the other matrix, to form the frame.

Description: Field of invention This invention concerns screens for use as filters in vibratory filtration equipment such as shakers that are used in the oil drilling industry for separating solids from the liquid phase of oil and water based muds retrieved from drilling operations. In particular the invention is concerned with the construction and manufacture of a wireframe reinforcement for embedding in a moulded support frame over which filtering material such as woven wire cloth is to be stretched and secured to form the screen. Background Examples of filtering machines in which such screens are used are contained in UK 2237521 and UK 2229771. One such screen is described in PCT/GB95/00411 (W095/23655). The earlier design of screen extends the life of a screen by providing a sacrificial support cloth of woven wire below an upper woven wire cloth of harder wearing material than that of at least the surface of the wire from which the lower cloth is woven, so that wear due to rubbing and vibration during use occurs to a greater extent in the lower cloth than in the upper cloth. The specification also describes an improved design of frame across which woven wire cloths can be tensioned and bonded by adhesive, to form a sifting screen, in which the frame is proposed to be formed from glass reinforced gas blown polypropylene with elongate metal reinforcing elements or rods buried in the GRP. The improved frame construction is shown in Figures 3 to 8 of the earlier specification. A moulded polymer support frame over which woven wire cloth is to be stretched and secured to form a sifting screen is constructed by the steps of locating in a mould tool a wire frame assembly comprising two parallel spaced apart arrays of reinforcing wires, closing the tool, injecting liquid polymer so as to wholly encapsulate the wire frame and to form an article having an open central region criss-crossed by intersecting orthogonal ribs bounded on all sides by a rigid flange, in which each of the ribs includes two parallel spaced apart wires of the said wire frame assembly, permitting the polymer to cure, opening the tool, and removing the moulded article. By arranging for two parallel spaced apart wires to extend through each of the ribs, one near one edge and the other nearer to the opposite edge of the rigs, each rib has the stiffness of a beam, and the resulting frame has high rigidity and resistance to bending, yet remains relatively lightweight. Such a moulded support frame will be referred to as a support frame of the type described. It is an object of the present invention to provide a method of constructing a wireframe reinforcement for such a support. Summary of the invention According to the present invention there is provided a method of making a reinforcing wire frame for embedding in a moulded polymer support frame over which woven wire cloth is to be stretched and secured to form a sifting screen, comprising the steps of: (a) locating lengths of cut wire in a jig to form a first array, said lengths being substantially equally spaced apart in the jig; (b) locating a second array of lengths of cut wire over the first array, the lengths of the second array being substantially at right angles to the lengths of wire of the first array; (c) resistance welding the lengths of wire of the first and second arrays at points of mutual intersection so as to form a first substantially rectilinear matrix; (d) locating lengths of cut wire in a jig to form a third array, said lengths being substantially equally spaced apart in the jig; (e) locating a fourth array of lengths of cut wire over the third array, the lengths of the fourth array being substantially at right angles to the lengths of wire of the third array; and (f) resistance welding the lengths of wire of the third and fourth arrays at points of mutual intersection so as to form a second substantially rectilinear matrix; characterised by the further steps of: (g) bending in a press break protruding lengths of wire on at least two sides of the four sides of one of the rectilinear matrices, so as to bend each protruding length of wire first in a generally upward sense and then at a point nearer its end in a generally downward sense so that an end region of each protruding length extends parallel to a plane of the matrix but is displaced therefrom; and thereafter (h) resistance welding the displaced ends of the protruding lengths of wire of said one matrix to protruding lengths of wire of the other matrix, so as to form the frame and maintain separation between the two matrices. Typically the wire frame is formed from high tensile straightened steel wire, bent as required, and in a preferred arrangement the wire is of 2.5mm diameter. The welding may be in part effected through the intermediary of transversely extending filler wires, so that intersections are provided where welds are to be formed between parallel protruding ends of the reinforcing wires, and the filler wires facilitate the resistance welding of the parallel protruding ends. Preferably the wire frame fabrication is assembled so that each matrix is bowed in an outward sense, opposite to the other. Other features of the invention are defined in the appended claims. Filtering machines of the type into which screens as aforesaid can be fitted, are described in UK Patent Specifications Nos. 2237521 and 2299771, but these are intended as examples only and the invention is not limited to the use of these screens in such machines. The invention will now be described by way of example, with reference to the accompanying drawings, in which: Figure 1 is a plan view of a frame over which wire cloths are to be stretched and secured to form a screen for use a filter in a vibratory filtration equipment such as a shaker for separating solids from the liquid phase of oil and water based muds; Figure 2 is a cross-sectional view at CC of Figure 1; Figure 3 is a part section at BB in Figure 1; Figure 4 is a part section on AA in Figure 1; Figure 5 is a part end view at D of the frame of Figure 1 to an enlarged scale; Figure 6 is a plan view to a reduced scale showing two screens, each constructed using a frame such as shown in Figure 1, in aligned edge abutting relation, to form a larger screening area; Figure 7 is a side elevation in the direction of arrow VII of Figure 6; Figures 8 or 9 show to an enlarged scale the two inter-engaging edge regions of the two frames of Figures 6 and 7; Figure 10 shows to enlarged scale in cross-section the abutting region of the two frames shown circled at VIII in Figure 7; Figure 11 is a plan view from above of another frame similar to that of Figure 1, but adapted to be joined in edge abutting relation with another similar frame so that the two frames are angled relative to one another when viewed from the side; Figure 12 is an end view at "B" in Figure 11; Figure 13 is a section on DD in Figure 11; Figure 14 is a part end view (to an enlarged scale) at "B" in Figure 11; Figure 15 is a part section at AA of the left hand end of the frame shown in Figure 11; Figure 16 is a part section at AA of the right hand end of the frame of Figure 11 showing in more detail the wire reinforcing structure, and where inserts are required to support it within a mould tool; Figure 17 is a part section at CC (to an enlarged scale) of the frame of Figure 11; Figures 17A and 17B show how the wire frame can be supported within a mould tool by ferrules which become an integral part of the moulded frame to cover the ends of the wires ; Figure 17C shows a bent-wire spacer to prevent wireframe collapse in the mould tool, as polymer is injected under pressure. Figure 18 is a side edge view of two frames of the type shown in Figure 11, in edge abutting engagement; Figure 18A is a view of the join to an enlarged scale; Figure 19 is a side elevation partly in cross-section of an intersection between row and column support members of a frame such as shown in Figure 1; Figure 20 is a top plan view of the frame part shown in Figure 19; Figure 21 is an elevation of a support for locating the wire reinforcing structure at a point of intersection as shown in Figures 19 and 20; Figure 22 is an end view to an enlarged scale of the lower end of the support of Figure 21; Figure 23 shows to a larger scale the preferred engagement of the chisel end of the stand off support with a reinforced rod; and Figure 24 shows part of a completed screen. Detailed description of the drawings Figure 1 illustrates a frame across which woven wire meshes are to be stretched and bonded in the manner herein described. The frame is generally designated 10 and includes a large number of similarly sized rectangular openings, one of which is denoted by 12 formed by a rectilinear matrix of orthogonally intersecting cross-members one of which is designated by 14 and another of which is designated by reference numeral 16. On two opposite sides, namely 18 and 20, the frame includes a relatively wide flange the upper surface of which is corrugated so as to form ridges and furrows 22. The other two edges 24, 26 and 28 are relatively narrow and include just two or three ridges 30, 32. By forming at least the ridges from a plastics material which can be softened on heating and which sets hard on cooling, woven wire meshes (not shown) can be stretched over the ridged peripheral regions of the frame and embedded in the ridges by heating the peripheral edges of the frame and pressing the wire meshes into the softened crests of the ridges. By allowing the plastics material to cool, so the wire meshes will be held firmly in place and if they are tensioned in both directions prior to the heating step and the tensions are maintained throughout, thereafter the plastics material has cooled, residual tensions will remain in the stretched layers of wire cloth. If as is usually preferred, the wire cloths have been differentially tensioned so that the tension in one is higher than that in the other, the differential will remain in the residual tensions retained in the wire cloths. By forming similar ridges along the top of each of the orthogonal cross-members, and arranging that the ridges of the cross-members are engaged by the wire cloth after the latter have become embedded in the ridges of the surrounding flanges, by heating over the whole surface area of the frame, so the woven wire meshes will become secured to the crests of the crossing members which when the assembly cools, will hold the woven wire cloths firmly in place, and provide additional support therefor. In a typical example, the first wirecloth will have a mesh size of approximately 30 and the second cloth a mesh size in the range 100-300. Each is made from annealed stainless steel wire - that making up the first cloth typically having a diameter of the order of 0.28mm. In accordance with a preferred aspect of the invention, the frame is formed from a plastics material which may be reinforced with glass fibres or similar reinforcing material and the edge regions and the crossing members of the frame are all reinforced with elongate steel wires which are welded together to form a wire frame reinforcing structure in a manner which will be described later. Typically steel wire of 2.5mm diameter is used to construct the reinforcing wire frame. A frame such as shown in Figure 1 is typically formed by inserting the reinforcing framework into a suitable mould tool and injecting plastics material under pressure into the tool so that the wire reinforcing frame becomes completely encased within plastics material (typically reinforced with glass fibre) so that on release from the mould, the reinforcing wires are totally encased within plastics material. The section at CC in Figure 2 shows the cross member 14 in section and the orthogonal cross member 16 is seen extending on either side of 14. The edge regions 18, 20 are reinforced by frame members 34 and 36. The cross-section at BB in Figure 1 is shown in Figure 3. The cross member 14 is still visible but the orthogonal cross member 38 is now shown intersecting 14 and the opening intersected by BB is denoted 40. Ridges such as 24 in the upper surface of the relatively wide edge flange 20 can be seen, as can also the inner of the two ridges along the narrower edge 28, namely ridge 42 which is also identified in Figure 1 for reference purposes. The ridged end 28 is cut away at opposite ends at 44, 46 as shown in Figure 1. Also shown in Figure 3 are some of the metal reinforcing rods forming the reinforcing framework. Two rods designated 48 and 50 extend through the upper and lower regions respectively of the cross member 38. Similar pairs of rods extend through the upper and lower regions of each of the parallel cross members such as 16. Through each of the orthogonally extending cross members designated 14 and 52 respectively, extend two similar pairs of rods designated 54 and 56, and 58 and 60 respectively. At the points of intersection between the rods they are welded together as by electric resistance welding. Further reinforcing rods 62 and 64 extend parallel to rods 54 and 58 through the edge region 20, and this is resistance welded to the extended ends of the rods 48 etc where they extend into the flange 20. The extensions of the lower rods such as 50 are bent upwardly as shown at 66 so as to extend co-extensively with or in contact with the underside of the upper rod of the pair eg extension of rod 48 and are resistance welded thereto. In this way the upper layer of intersecting and welded rods such as 48, 54, 58, 62, 64 is secured to the lower layer of rods such as 50, 56, 60, to form a unitary reinforcing structure. Figure 4 is a part section on AA to a larger scale than Figure 1 which allows the ridges 30 and 32 to be seen in section at the ends of the frame which are to be butt-joined. Figure 4 also shows detail of the male and female locking arrangement at opposite ends of the frame. Thus at the left hand end an elongate protrusion 68 stands off from the left hand end face 70 and extends across the entire width of the frame, whilst at the other end of the frame the end face 72 is cutaway to define a rebate 74 to receive the protrusion 68 of an abutting frame. The end face 72 also includes an upstand 76 which cooperates with the opposite end region of the end face 70 of the abutting frame, to space the two end faces from each other by the thickness of the upstand 76. This also assists in seating the rebate 78 in the protrusion 68 correctly below the lp 80 along the upper edge of the rebate 74. Figure 4 also shows the small openings which can be left above the intersection point of the reinforcing grid, if stand-off pits, or stools, are used in the mould tooling to position the reinforcing grid within the tooling. Two of these are visible at 82 and 84. Figure 5 is a part end view in the direction of arrow D in Figure 1 and shows the upstand 76 and the end face 72 of the right hand end of the frame as depicted in Figure 4. Likewise the lip 80 is also shown together with the undercut 86 in the underside of the shoulder created by the rebate 74. Figure 6 shows how two frames 10 and 10' each similar to that shown in Figure 1 can be joined, with the two edges 26', 28 abutting/engaged as will be described more fully with reference to later figures of the drawings. In use the wider flanges 18 and 20, 18' and 20' and one end flange 28' are gripped in an appropriate manner within the basket of a shaker assembly. The end flange 20 may in fact only be supported on its underside in order to permit solids material to progress over that edge unimpeded during shaking. An inflatable grip seal may be used along the edges 20, 20', 28', 18' and 18. As shown in Figure 7, the two frames 10 and 10' may be aligned and in some shakers advantageously the aligned frames are mounted so as to be inclined to the horizontal so as to describe an uphill slope up which the mud which is to be filtered climbs as a result of the shaking movement. Typically the shaking movement has components generally in the direction of the alignment of the two frames and generally perpendicular thereto. The two separate parts forming the abutment are shown to an enlarged scale in Figures 8 and 9, and detail of the engagement is shown in Figure 10. Figure 9 shows the edge 28 which includes the protruding nose generally designated 68 which extends across the width of the frame and fits below the shoulder 80, of the rebate 74 of the cooperating frame 10. The upstand 76 may comprise a separate member in the form of a seal which may be of plastics material or rubber or a composite thereof. Alternatively as shown it may simply comprise a protruding ridge formed during moulding, in the material from which the rest of the frame is constructed. When mounting the two frames in a shaker, frame 10' is first introduced into the shaker basket and thereafter frame 10. By raising the right hand end of frame 10 (as viewed in Figure 6) so that the frame 10 is angled relative to the plane of frame 10', the nose 68 can be inserted below the shoulder 80 into the undercut 86 of the rebate 74 so that the ridge 88 of the protrusion 68 engages in the undercut 86 behind the shoulder 80. Once 88 is within 86, the frame 10 can be lowered so as to be in alignment with 10' and by choosing the dimensions carefully, in that condition only, the inclined surface 90 engages the inclined underside 92 and the upstand 76' makes contact with the face 70 of the other frame end. This is more clearly shown in Figure 10. By dimensioning thus any fluid trapped between the ends of the frame as the two frames are pushed together, can be squeezed through the gap left between the surfaces to facilitate drainage through the lowermost gap visible in Figure 10. In some shakers, it is preferred that the two screens such as shown in Figure 6, (each formed by a frame with woven meshes stretched thereover) are inclined relative one to the other instead of being aligned as shown in Figure 7. To this end an alternative edge configuration may be incorporated, by arranging that one frame end can be fitted into the other with a small step between the two upper surfaces. Figure 11 is a plan view of such a frame. Figures 12, 13 and 14 provide edge and section views to an enlarged scale of the case of Figure 14, of the frame shown in Figure 11. Essentially the construction of the central area of the frame is similar to that of the frame of Figure 1. Thus the meshes are secured to external flanges 100, 102, 104 and 106 and to the upper edges of intersecting orthogonal cross members such as 108, 110, 112 etc. The relatively wide flanges 100 and 102 are visible in Figures 12 to 14, together with the cross members 110, 112. Each of the intersecting cross members is ridged along its upper edge as best seen from the hidden detail of items 110, 112 in Figure 14. The ridges are identified by reference numerals 114, 116 and it will be noted that the peaks of the ridges 114, 116 are just below the peak of the ridges 118 along edge 106 (see Figure 11). This ensures that when the GRP material is heated to accommodate the wire meshes, the heating and welding of the meshes to the outer regions 100 to 106 of the frame occurs prior to that over the central region made up of intersecting cross members 108, 110 etc. The ends 104, 106 are designed to be capable of interengagement and accordingly the end 106 is formed with a pair of jaws 120, 122 which extend across the entire width of the frame end and can receive the opposed end 104 of a second frame (not shown). This opposed end comprises an extended flange 124 having three ridges 126 formed in its upper surface, the height of the flanges combined with the thickness of the flange 124 being equal to the internal spacing between the upper and lower jaws 120, 122, so that an end 124 can be pushed into the elongate slot formed by a pair of jaws 120, 122. At 128 the underside of the upper jaw diverges upwardly away from the lower jaw, to assist in entering the end 124 therein. Being formed from a plastics based material, the ridges 126 are deformable, and by dimensioning the gap between the jaws 120, 122 accurately, so the flange 104 can become firmly wedged in the gap between those jaws, the ridges 126 forming a partial seal between the flange 124 and the underside 128 of the upper jaw 120 of end flange 106. As with the frame illustrated in Figures 1 to 10, the frame of Figure 11 includes a grid of reinforcing rods, welded or otherwise joined at the interstices of the grid, and constructed from upper and lower layers - generally designated 130, 132 respectively - see Figure 15. The ends of the lower layer of rods are bent upwardly as at 134 in Figure 16 to be welded to the aligned rods of the upper layer in the end flange 104. The upper and lower layers of rods terminate without converging at the other end of the frame as can be seen from the part section of Figure 15. The two edges 100 and 102 are reinforced in the same way as is end flange 104, and the ends of the rods 136 of the lower layer are bent upwardly as at 138 in Figure 17, to merge with and be welded or otherwise joined to the upper rods 140. All the rods are wholly contained within the rectilinear array of intersecting cross members except at the flanged edges of the frame. The part section of Figure 17 is taken on the line CC in Figure 11 and cross members 110 and 112 are denoted in both figures. Figure 18 shows how two frames such as shown in Figures 11 to 17 can be fitted so that one lies at a shallow angle relative to the other. The one frame is denoted 14. Figure 18A shows a modified interengagement possibility similar to the engagement of an end such as 126 in an elongate "socket" between jaws such as 120, 122 - but in which both ends are "female" (ie equivalent to end 106), and the upper flange of the one can be received and wedged, into the socket of the other and a good seal is maintained. Similar reference numerals are employed to denote items in common as between Figure 18A and earlier and later figures. As also shown in Figure 17, plastics support inserts or stools such as denoted by 142, 144 may be located in the mould tool so as to engage the interstices of the intersecting rods, thereby to correctly space the framework within the mould tool when the latter is closed. In an alternative spacing arrangement, the spacing and positioning may be achieved by fingers protruding from the inside surfaces of the mould tool, and any openings in the plastics moulding may be filled by appropriate material after the tool has been opened and the moulded component has been removed, or may be filled by the plastics material from which the struts are formed when the frame is subjected to heat and pressure during the manufacturing process. Preferred arrangements utilise stand-off supports or stools since these can be used not only to centre the reinforcing framework within the mould tool, but where the framework has been constructed so as to bow slightly upwardly and downwardly, they will redefine the correct spacing between the upper and lower arrays of rods, when the mould tooling is closed. A preferred form of such stand-off support is illustrated and described with reference to Figures 19 to 23. In order to prevent moulding pressure within the tooling from forcing the upper and lower walled arrays of rods/wires together so as to reduce the spacing therebetween, spacers 143 (typically bent wires, formed to one or other of the two arrays and permitting relative movement towards each other beyond a critical dimension defined by the spacers) are provided, as shown in Figure 17C. In a similar way, plastic ferrules such as that shown in Figure 17 and denoted by 146, can be inserted into the mould tool so as to cover the ends of the rods which might otherwise be left exposed. In a preferred mould tool, the welded reinforcing framework is supported in one part of the tooling by four retractable pins (145), two on opposite sides of the framework, by means of double ended plastics ferrules (146) which are each fitted at one end onto an end of one of the rods (140) making up the framework, and at the other end onto one of the retractable pins. After moulding, the pins (145) are retracted from the blind holes in the ferrules (146) which will have been embedded in the GRP during moulding, to permit the moulded article to be removed from the tooling. An example is shown in Figures 17A and 17B. Where support inserts or ferrules protrude after moulding, they can be removed by cutting or filing. As mentioned in relation to Figures 11 et seq, the crests of the ridges in the edge flanges of the frame shown in Figures 1 to 10 may also lie in a different plane from the crests of the ridges on the cross members such as 14 and 16, and in a preferred arrangement one or more of the outer ridges along the flanges such as 18, 20, 26 and 28 extend(s) above the plane containing the crests of the crests of the cross members such as 14, 16. In this way the peripheral regions of the frames contain a greater amount of plastics material to be heated and softened before the woven wire mesh cloth can be forced thereinto, than exists along the cross-members. Bonding of the peripheral regions therefore has to occur before the cloths can come into contact with, and become bonded into the crests of the cross members 14, 16 etc. Figures 19 to 23 show, to different, and generally an enlarged scale, the location of preferred stand off supports for the reinforcing rods. Here each support comprises a tapering chisel-ended metal pin 148 as shown in Figure 19. The chisel end 150 is best seen in Figure 21. As shown in Figure 23, the pins are arranged so that each chisel end 150 extends generally perpendicularly to the length dimension of the rod 48 which it will engage in the mould tool. By virtue of the chisel end 150, and the taper 152, liquid plastic material flows around the tapering, chisel ends in such a way as to leave similarly tapering recesses such as 154 in the crests of the cross members of the frame when the tool is opened and the chisel ends are extracted from the moulding. Each recess left by a pin 148 therefore only exposes a tiny area 156 of the wire (see Figure 20). When woven wire cloths are stretched over the crests of the frame and the cloths and frame are heated, the plastics material flows into the lower end of each recess left by a chisel end, such as 150. This fills the tiny area to provide a barrier between the wire mesh(es) and the reinforcing rods such as 48 (see Figure 3). Figure 24 is a perspective view of the female end of the frame 10' of Figure 9. The sealing ridge 76 can be seen above the groove 74 into which the elongate male "nose" 68 (see Figure 9) fits. Across the frame are stretched woven wire cloths, the upper one of which is shown in part at 158 and the lower, in part, at 159. Two such cloths, one above the other, are stretched over the frame, the mesh of the lower cloth being coarser than that of the upper cloth, and with the tension in the lower cloth being greater than that in the upper. By heating at least the upper surface of the frame, and applying uniform downward pressure on the cloths, the crests of the plastics frame will soften and allow the wire cloths to sink into the crests, which will also become flattened into the process. On cooling the plastics material hardens and secures the wire cloths in place. The crests of the outermost ridges 160 on the flange extend upwardly above the crests of the inner ridges of the same flange. The land area at the junction between two screens such as shown in Figures 7 and 18 should be as small as possible so as not to impede the progress of particulate material from one screen to the next. Likewise the front edge of the screen where solids traverse over and off the edge, for example into a skip, should also be as small in area as possible. The joint provided by interfitting ends such as shown in Figures 18, 18A, causes the edge 120 of the upper frame to overlie wire mesh of the lower frame. The non-screening dead area is thereby reduced to the minimum, ie the ridged end 120. The joint provided by the engagement such as shown in Figures 18, 18A also seals the joint and prevents fluid leakage, and has been found to reduce the risk of bounce between one frame and the other across the joint. This appears to be achieved due to the formation of a structural member by the reinforcing wires and where these are tensioned, as is the case when the framework is pushed from above and below in the mould tool, the framework and plastics material will significantly resist bending and therefore minimise any tendency to bounce. Flash heating is preferably used to bond the wire cloths to the crests. Weld wires are conveniently employed between overlying parallel rods such as 48, 66 (see Figure 3) as designated by reference numeral 49. The drawings and related description of UK Patent Specifications 2237521 and 2299771 are referred to as illustrating filtering machines of the type in which screens as described herein may be mounted.

Claims: A method of making a reinforcing wire frame for embedding in a moulded polymer support frame over which woven wire cloth is to be stretched and secured to form a sifting screen, comprising the steps of: (a) locating lengths of cut wire (54, 58, 62, 64) in a jig to form a first array, said lengths being substantially equally spaced apart in the jig; (b) locating a second array of lengths of cut wire (48) over the first array, the lengths of the second array being substantially at right angles to the lengths of wire of the first array; (c) resistance welding the lengths of wire of the first and second arrays at points of mutual intersection so as to form a first substantially rectilinear matrix; (d) locating lengths of cut wire (50) in a jig to form a third array, said lengths being substantially equally spaced apart in the jig; (e) locating a fourth array of lengths of cut wire (56, 60) over the third array, the lengths of the fourth array being substantially at right angles to the lengths of wire of the third array; and (f) resistance welding the lengths of wire of the third and fourth arrays at points of mutual intersection so as to form a second substantially rectilinear matrix; characterised by the further steps of: (g) bending in a press break protruding lengths of wire on at least two sides of the four sides of one of the rectilinear matrices, so as to bend each protruding length of wire (66) first in a generally upward sense and then at a point nearer its end in a generally downward sense so that an end region of each protruding length extends parallel to a plane of the matrix but is displaced therefrom; and thereafter (h) resistance welding the displaced ends of the protruding lengths of wire (66) of said one matrix to protruding lengths of wire (48) of the other matrix, so as to form the frame and maintain separation between the two matrices. A method as claimed in claim 1 wherein the wire frame is formed from high tensile straightened steel wire, bent as required. A method as claimed in claim 2 wherein the wire is of 2.5mm diameter. A method as claimed in claim 1, 2 or 3 wherein the welding is at least in part effected through the intermediary of transversely extending filler wires (49), so that intersections are provided where welds are to be formed between parallel protruding ends of the reinforcing wires, and the filler wires facilitate the resistance welding of the parallel protruding ends. A method as claimed in any of claims 1 to 4 wherein the wire frame fabrication is assembled so that each matrix is bowed in an outward sense, opposite to the other. A method as claimed in any of claims 1 to 5 wherein a plurality of spacers (143) are located within the wire frame fabrication, each attached to one or other of the matrices so as to extend towards the other, to resist any tendency for the matrices to collapse inwards during moulding. A method as claimed in claim 6 wherein each spacer (143) comprises a length of wire bent to form a shallow U with its two ends bent outwards to form two in-line lugs by which it can be welded to the underside of one of the wires which form one of the matrices, with the crest of the U section in close proximity to one of the wires of the other matrix, whereby the spacer will maintain a given dimension between the two matrices if the fabrication is subjected to a collapsing force during moulding, so causing the crest to engage the said wire of the other matrix. A reinforcing wire frame for embedding in a moulded polymer support frame (10), made in accordance with claim 1 and constructed from two similar rectangular arrays of resistance welded wires, wherein protruding wires (66) along at least two sides of one of the arrays are bent so as to make contact with reinforcing wires (48) of the other array, and the ends of the bent portions of the wires (66) of the one array are resistance welded to the protruding ends of the wires in the other array, to form the frame and to maintain separation between the two matrices, each reinforcing wire (48) which aligns with a peripheral flange (18, 20) of the support frame extending into the flange at each end thereof, thereby to increase the rigidity of the flange, the ends of the other wire (66) of the pair being bent so as also to become aligned with the flange, and the bent ends thereof extending into the flanges close to the ends of the first mentioned wire (48) to further assist in reinforcing the flanges when formed, and wherein further reinforcing is provided for the flanges (18, 20) by means of additional reinforcing wires (62, 64) extending parallel to what will be the length direction of the flanges, so as to overlie or underlie the protruding reinforcing wires entering the flanges from struts (14, 16) of the support frame (10), the additional reinforcing wires being welded to the protruding reinforcing wire ends.

Inventors: BAILEY ARTHUR ROBERT, COOK GORDON JAMES, HARTNUP GEORGE CHARLES, HUGHES ANDREW, STEWARD DUGALD, BAILEY, ARTHUR ROBERT, COOK, GORDON JAMES, HARTNUP, GEORGE CHARLES, HUGHES, ANDREW, STEWARD, DUGALD
Applicants: UNITED WIRE LTD, UNITED WIRE LIMITED
Application year: 1998
Main classification: B07B1
IPC codes: B07B1, B29C70, B01D29, B01D33