Apparatus for making inflated plastic mesh

Claim 2

An inflated plastic mesh forming apparatus, comprising: a die body to hold a supply of extrudable plastic; a first movable die plate having a first set of extrusion orifices terminating in a first series of discharge openings for extruding a first group of filaments; a second die plate having a second set of extrusion orifices terminating in a second series of annular discharge openings, said second die plate being movable relative to said first die plate for extruding a second group of hollow filaments intersecting and bonded to said filaments of said first group at said intersections to define a mesh; gas pressure means terminating within each of said annular discharge openings to force a gas into said hollow filaments to inflate said hollow filaments; and sealing means for sealing said gas within said inflated filaments.

Claim 3

Apparatus according to claim 1, wherein the discharge openings in each of said die plates are spaced from the edges of said die plates.

Claim 4

Apparatus according to claim 1, including a liquid bath for cooling the mesh after extrusion.

Claim 5

Apparatus according to claim 1, wherein: said discharge openings in said first movable die plate are arranged in a first extrusion circle; said discharge openings in said second movable die plate are arranged in a second extrusion circle concentric with said first extrusion circle; and including means to rotate said first die plate relative said second die plate.

Claim 6

Apparatus according to claim 4, including: an elongated member centrally supported within each of said extrusion orifices in said second die plate; a gas compressor; a gas passage centrally through each of said elongated members; and conduit means in communication with said gas compressor and said gas passages to conduct gas into said hollow filaments, Said annular discharge openings in said second die plate being defined by the annular space between said elongated members and the walls of said extrusion orifices in which each elongated member is supported.

Claim 7

Apparatus according to claim 5, wherein, said elongated member is supported in said extrusion orifice by a spider support from the walls of said extrusion orifice, said spider support being spaced from said annular discharge opening to permit plastic to flow uninterrupted from said annular discharge opening.

Claim 8

Apparatus according to claim 4, including: a mandrel concentric with and having a diameter greater than the diameter of said first and said second extrusion circles for sizing the mesh; and cutting means having a knife edge, said knife edge being maintained between two adjacent inflated filaments to cut the filaments of said first group.

Claim 9

Apparatus according to claim 7, wherein said second die plate and said cutting means are maintained stationary.

Claim 10

Apparatus according to claim 4, wherein said sealing means comprises heat sealing means for sealing said inflated filaments across the width thereof.

Claim 11

Apparatus according to claim 9, wherein said heat sealing means includes a heated member disposed transverse said inflated filaments and means to actuate said heated member into contact with the mesh to heat seal together opposing walls of said inflated filaments at predetermined intervals to entrap said gas within said inflated filaments.

Claim 12

Apparatus according to claim 9, wherein said heat sealing means includes: a rotatable member having at least one outer heated surface; and means to rotate said rotatable member into intermittent contact with said inflated filaments to form a linear series of sealed, inflated chambers in said inflated filaments.

Claim 13

Apparatus for forming an inflated plastic mesh, comprising: a die body to hold a supply of extrudable plastic; a first movable die plate having a first set of extrusion orifices terminating in a first series of discharge openings arranged in a first extrusion circle for extruding a first group of filaments; a second die plate having a second set of extrusion orifices terminating in a second series of annular discharge openings arranged in a second extrusion circle concentric with said first extrusion circle for extruding a second group of hollow filaments; means for moving said first die plate relative said second die plate for intersecting and bonding said filaments of said first group to said filaments of said second group at said intersections; gas pressure means terminating in each of said annular discharge openings to force a gas into said hollow filaments to inflate said hollow filaments; and sealing means for sealing said gas within said inflated filaments.

Claim 14

Apparatus for forming an inflated plastic mesh, comprising: a die body to hold a supply of extrudable plastic; a first movable die plate having a first set of extrusion orifices terminating in a first series of discharge openings arranged in a first extrusion circle for extruding a first group of filaments; a second die plate having a second set of extrusion orifices terminating in a second series of annular discharge openings arranged in a second extrusion circle concentric with said first extrusion circle for extruding a second group of hollow filaments; means for moving said first die plate relative said second die plate for intersecting and bonding said filaments of said first group to said filaments of said second group at said intersections; gas pressure means terminating in each of said annular discharge openings to force a gas into said hollow filaments to inflate said hollow filaments; and sealing means for sealing said gas within said inflated filaments.

Claim 15

Apparatus according to claim 12, including: a mandrel concentric with and having a diameter greater than the diameter of said first and second extrusion circles for sizing the mesh; and cutting means having a knife edge, said knife edge being maintained between two adjacent inflated filaments to cut the filaments of said first group.

Claim 16

Apparatus according to claim 13, wherein said sealing means includes a heated member disposed transverse said inflated filaments and means to actuate said heated member into contact with the mesh to heat-seal together opposing walls of said inflated filaments at predetermined intervals to entrap said gas within said inflated filaments.

Claim 17

Apparatus according to claim 14, wherein said heat sealing means includes a rotatable member having at least one outer heated surface and means to rotate said rotatable member into intermittent contact with said inflated filaments to form a linear series of sealed, inflated chambers in said inflated filaments.

Claim 18

Apparatus according to claim 15, wherein the outer heated surface of said rotatable member includes a plurality of notches adapted to straddle said non-inflated filaments.