Matrix fabrication

Claim 2

In welding apparatus for fabricating a welded wire, threedimensional rectilinear matrix having strut members traversing the interior of the matrix between opposite major surfaces of the matrix, the apparatus comprising coaxially aligned first and second electrodes, means mounted the first and second electrodes for movement along their common axis toward each other into a welding position thereof and away from each other into a retracted position thereof, and a central electrode, the improvement comprising, in combination, means mounting the central electrode for movement along a first path substantially normal to said axis within the matrix independently of movement of the matrix along the first path relative to the first and second electrode between a welding position in which the central electrode intercepts said axis to serve as a conductive anvil for the first and second electrodes and a retracted position spaced from said axis, the retracted position of the electrodes accommodating movement along a second path substantially normal to the first path of material welded and to be welded out of and into place between the first and second electrodes across said axis, such movement of material at times including movement of at least one of the strut members across said axis through the welding position of the central electrode, and means coupled to the central electrode operable for moving the central electrode along said first path between the welding and retracted positions of the central electrode.

Claim 3

Apparatus according to claim 1 wherein the central electrode is arranged to serve as a conductive anvil for the first and second electrodes simultaneously.

Claim 4

Apparatus according to claim 1 comprising a first, second and central electrode at each of a plurality of spaced welding stations within the apparatus, the first and second electrodes at all stations being disposed parallel to a common plane, means operative upon first matrix components to be welded at all of said stations for moving said first components at each station along the corresponding second path concurrently with movement of said components at the other stations, and means coordinating operation of the means for moving the several central electrodes so that the central electrodes are moved together between their welding and retracted positions along said first paths substantially parallel to said plane, the second paths for the several stations being substantially normal to said plane.

Claim 5

Apparatus according to claim 3 wherein the central electrodes at the several stations are movable parallel to said common plane.

Claim 6

Apparatus according to claim 3 wherein said first components to be welded comprises a matrix subunit for each welding station, the subunits adjacent their respective welding stations being disposed in spaced parallel secondary planes substantially normal to said common plane and substantially parallel to the axes of said first and second electrodes at the respective welding stations, each subunit comprising a pair of spaced wires extending along the length of the subunit along opposite margins thereof and a plurality of matrix strut members connected between said wires at spaced locations along the subunit, and wherein the central electrode at each station, when in its welding position, traverses the corresponding second plane.

Claim 7

Apparatus according to claim 5 including means for moving second matrix components to be welded along a line substantially parallel to said common plane into place between the first and second electrodes at each welding station, for affixation to the matrix subunits to interconnect the subunits to define the matrix.

Claim 8

Apparatus according to claim 3 wherein the common axes of the first and second electrodes at the welding stations are parallel to each other.

Claim 9

Apparatus according to claim 7 wherein the first and second electrodes are disposed in said common plane.

Claim 10

APparatus according to claim 3 including means for driving the first and second electrodes at each welding station toward and away from each other when the corresponding central electrode is in its welding position, means for moving second components of the matrix in said common plane into position to be welded between the first and second electrodes at each station, and means for operating the component moving means associated with each welding station when the corresponding central electrode is in its retracted position.

Claim 11

Apparatus according to claim 9 wherein said driving means for the several welding stations are operative in tandem and said first component moving means are common to the several welding stations.

Claim 12

Apparatus according to claim 10 wherein the matrix is comprised of a plurality of essentially identical truss sections each having a pair of parallel spaced runner members extending the length thereof and a plurality of strut members interconnected between the runner members at regularly spaced locations along the truss section, and the matrix is further comprised of a plurality of regularly spaced members each disposed parallel to the others thereof transversely of the truss sections and connected to a runner member of each of the truss sections at correspnding locations spaced regularly along each said transverse member, the transverse members comprising said first component of the matrix and the truss sections comprising said additional components of the matrix.

Claim 13

In apparatus for the fabrication of a welded wire, three-dimensional rectilinear matrix having major dimensions in opposite major surfaces of the matrix and a minor dimension between the major surfaces, the matrix being comprised of a plurality of spaced matrix subunits extending in respective planes substantially parallel to one of the matrix major dimensions and of a plurality of spaced interconnect members extending substantially parallel to the other matrix major dimension and interconnecting the subunits in each major surface of the matrix, the interconnect members being disposed in pairs in which the members thereof are disposed in a plane substantially perpendicular to the matrix major surfaces, each subunit having longitudinal elements spaced in the subunit plane a distance essentially equal to the matrix minor dimension and a plurality of strut members interconnected in the subunit between the longitudinal elements at spaced locations along the subunit, the improvement comprising means for applying welding force between and interconnect member and a subunit longitudinal element along a line normal to the matrix major surface associated with said member and element, said means including an outer electrode disposed outside the matrix major surfaces, and an inner electrode disposed between the matrix major surfaces, the inner electrode having a welding position aligned with the outer electrode and traversing the corresponding subunit plane, and means for moving the inner electrode in the matrix relative to the matrix out of alignment with the outer electrode and out of the subunit plane independently of movement between the matrix and the outer electrode to permit the matrix and the electrodes to be moved relative to each other in a work advancing manner.

Claim 14

In apparatus for the fabrication of a welded wire, three-dimensional rectilinear matrix having major dimensions in opposite major surfaces of the matrix and a minor dimension between the major surfaces, the matrix being comprised of a plurality of spaced matrix subunits extending in respective planes substantially parallel to one of the matrix major dimensions and of a plurality of spaced interconnect members extending substantially parallel to the other matrix major dimension and interconnecting the subunits in each major surface of the matrix, the interconnect members being disposed in pairs in which the members thereof are disposed in a plane substantially perpendicular to the matrix major surfaces, each subunit having longitudinal elements spaced in the subunit plane a distance essentially equal to the matrix minor dimension and a plurality of strut members interconnected in the subunit between the longitudinal elements at spaced locations along the subunit, the improvement comprising means for applying welding force between and interconnect member and a subunit longitudinal element along a line normal to the matrix major surface associated with said member and element, said means including an outer electrode disposed outside the matrix major surfaces, and an inner electrode disposed between the matrix major surfaces, the inner electrode having a welding position aligned with the outer electrode and traversing the corresponding subunit plane, and means for moving the inner electrode in the matrix relative to the matrix out of alignment with the outer electrode and out of the subunit plane independently of movement between the matrix and the outer electrode to permit the matrix and the electrodes to be moved relative to each other in a work advancing manner.

Claim 15

Apparatus according to claim 12 wherein the welding force applying means includes coaxially aligned opposed movable upper and lower electrodes, one of the upper and lower electrodes comprising the aforesaid outer electrode, means for moving the upper and lower electrodes along paths normal to the matrix major surfaces between retracted positions thereof spaced a distance greater than the matrix minor dimension and welding positions in which each of said electrodes forceably engages an interconnect member between it and a matrix subunit longitudinal element when a matrix interconnect member is disposed between said electrode and the matrix subunit, a central electrode comprising the aforesaid inner electrode and sized tO be disposed between and clear of adjacent matrix subunits for work-advancing movement of the adjacent subunits relative to the central electrode, and the aforesaid means for moving the inner electrode includes means for moving the center electrode within the matrix while the matrix is stationary relative to the inner and outer electrodes between a retracted position in which the center electrode is disposed wholly between adjacent matrix subunits out of coaxial alignment with the upper and lower electrodes to thereafter accommodate said work-advancing movement and a welding position within a matrix subunit in which the central electrode is disposed for cooperation coaxially with the upper and lower electrodes to define a conductive path from at least one of the upper and lower electrodes through an interconnect member engaged by said one electrode and through a subunit longitudinal element to the central electrode.

Claim 16

Apparatus according to claim 13 wherein the central electrode is configured to define, in the welding position thereof, a conductive path between the upper and lower electrodes via the longitudinal elements of a subunit within which the central electrode is disposed and via an interconnect member engaged with each said longitudinal element.

Claim 17

Apparatus for fabricating a strip of serially connected identical constructions in which corresponding locations in a predetermined number of constructions are spaced a predetermined distance apart along the strip, the apparatus comprising a conveyor belt loop the length of which defines said predetermined distance, means for driving the belt continuously along a desired path, means carried by the belt for receiving said components of a construction and for supporting received components in predefined positions relative to each other, means cooperating with the belt along said path for connecting together in said predefined positions components supported on the belt thereby to define the constructions and the strip thereof, and means operative upon a selected point on the belt during driving of the belt for altering the effective length of the belt to maintain said predetermined distance.

Claim 18

Apparatus for fabricating a strip of serially connected identical constructions in which corresponding locations in a predetermined number of constructions are spaced a predetermined distance apart along the strip, the apparatus comprising a conveyor belt loop the length of which defines said predetermined distance, means for driving the belt continuously along a desired path, means carried by the belt for receiving said components of a construction and for supporting received components in predefined positions relative to each other, means cooperating with the belt along said path for connecting together in said predefined positions components supported on the belt thereby to define the constructions and the strip thereof, and means operative upon a selected point on the belt during driving of the belt for altering the effective length of the belt to maintain said predetermined distance.

Claim 19

Apparatus according to claim 15 including means for generating a signal when the distance along the strip between corresponding locations of a predetermined number of constructions differs by a selected amount from the predetermined distance, and means responsive to the signal for operating the belt length altering means to reduce the difference.

Claim 20

Apparatus according to claim 16 wherein the belt length altering means includes means for interconnecting opposite ends of the belt to define the belt loop.

Claim 21

Apparatus according to claim 15 wherein the means for connecting together components supported on the belt comprises means for welding said components together, said components being electrically conductive, and wherein the component supporting means carried by the belt include means defining a portion of a conductive path within the belt along which welding current flows during welding of said components.

Claim 22

Apparatus according to claim 18 wherein the construction components comprise a pair of spaced parallel members extending the length of the construction along opposite margins thereof, the marginal members of each construction being common to the adjacent constructions in the strip, and a plurality of transverse members each extending between and connected to the opposite marginal members at intervals along the strip, and wherein the means for receiving and supporting the construction components comprises a corresponding plurality of electrically non-conductive carrier blocks for receiving and positioning first the marginal members and a corresponding transverse member with one of the transverse member or the marginal members disposed at least partially above the top of the block, each block including means defining a conductive path through the block between the location of engagement of the traNsverse member with one marginal member and the location of engagement of the transverse member with the other marginal member.

Claim 23

Apparatus according to claim 19 wherein the belt comprises a length of link chain to which the chain blocks are mounted.

Claim 24

Welding apparatus for fabricating a welded wire three-dimensional rectilinear matrix comprised of a plurality of essentially identical truss sections, each truss section having a pair of parallel runner members extending the length thereof and a plurality of strut members interconnected between the runner members at regularly spaced locations along the truss section, the matrix being further comprised of a plurality of regularly spaced members each disposed parallel to the others thereof transversely of the truss sections substantially normal to the planes of the truss sections and connected to a runner member of each truss section at corresponding locations regularly spaced along each said transverse member, whereby corresponding truss section runner members and transverse members connected thereto define opposite major surfaces of the matrix which are spaced from each other a distance corresponding to the spacing between the runner members of each truss section, and whereby the strut members of the several truss sections traverse the interior of the matrix between the opposite major surfaces thereof, said welding apparatus including apparatus for welding the elements of the truss sections together comprising a conveyor belt loop for receiving and supporting the truss runners and the strut members, in predetermined positions for and during welding means for driving the belt loop, and means operative at a selected location on the belt loop during driving of the belt loop for altering the effective overall length of the belt loop, said welding apparatus also including apparatus for welding the transverse members to the truss sections comprising coaxially aligned first and second electrodes reciprocal toward and away from each other along their common axis, and a central electrode mounted for movement between a welding position in which the central electrode intercepts said axis to serve as a conductive anvil for the first and second electrodes and a retracted position spaced from said axis to accommodate movement of said truss sections and the transverse members into and out of place between the first and second electrodes across said axis

Claim 25

Welding apparatus for fabricating a welded wire three-dimensional rectilinear matrix comprised of a plurality of essentially identical truss sections, each truss section having a pair of parallel runner members extending the length thereof and a plurality of strut members interconnected between the runner members at regularly spaced locations along the truss section, the matrix being further comprised of a plurality of regularly spaced members each disposed parallel to the others thereof transversely of the truss sections substantially normal to the planes of the truss sections and connected to a runner member of each truss section at corresponding locations regularly spaced along each said transverse member, whereby corresponding truss section runner members and transverse members connected thereto define opposite major surfaces of the matrix which are spaced from each other a distance corresponding to the spacing between the runner members of each truss section, and whereby the strut members of the several truss sections traverse the interior of the matrix between the opposite major surfaces thereof, said welding apparatus including apparatus for welding the elements of the truss sections together comprising a conveyor belt loop for receiving and supporting the truss runners and the strut members, in predetermined positions for and during welding means for driving the belt loop, and means operative at a selected location on the belt loop during driving of the belt loop for altering the effective overall length of the belt loop, said welding apparatus also including apparatus for welding the transverse members to the truss sections comprising coaxially aligned first and second electrodes reciprocal toward and away from each other along their common axis, and a central electrode mounted for movement between a welding position in which the central electrode intercepts said axis to serve as a conductive anvil for the first and second electrodes and a retracted position spaced from said axis to accommodate movement of said truss sections and the transverse members into and out of place between the first and second electrodes across said axis

Claim 26

Apparatus according to claim 21 wherein the truss section welding apparatus is operative to define said truss sections as a strip of serially connected truss sections, means for generating a signal when the length of a predetermined number of truss sections in said strip differs by a selected amount from a preset standard length thereof, and means responsive to the signal for operating the belt loop length altering means.

Claim 27

Resistance welding apparatus comprising, coaxially aligned first and second electrodes, means mounting the first and second electrodes for movement along their common axis toward each other into a welding position thereof and away from each other into a retracted position thereof, and a central electrode, means mounting the central electrode for movement along a first path substantially normal to said axis of the first and second electrodes between a welding position in which the central electrode intercepts said axis to serve as a conductive anvil for the first and second electrodes and a retracted position spaced from said axis, the retracted position of the electrodes accommodating movement along a second path substantially normal to the first path of material welded and to be welded out of and into place between the first and second electrodes across said axis, such movement of material at times including movement of an element of the work for the apparatus across said axis through the welding position of the central electrode, and means coupled to the central electrode operable for moving the central electrode along said first path Between the welding and retracted positions of the central electrode.

Claim 28

Resistance welding apparatus comprising, coaxially aligned first and second electrodes, means mounting the first and second electrodes for movement along their common axis toward each other into a welding position thereof and away from each other into a retracted position thereof, and a central electrode, means mounting the central electrode for movement along a first path substantially normal to said axis of the first and second electrodes between a welding position in which the central electrode intercepts said axis to serve as a conductive anvil for the first and second electrodes and a retracted position spaced from said axis, the retracted position of the electrodes accommodating movement along a second path substantially normal to the first path of material welded and to be welded out of and into place between the first and second electrodes across said axis, such movement of material at times including movement of an element of the work for the apparatus across said axis through the welding position of the central electrode, and means coupled to the central electrode operable for moving the central electrode along said first path Between the welding and retracted positions of the central electrode.