Abstract: A wire mesh rivet (13) is provided which is used to produce a wire mesh isolator (11) in a bore (9) of a substrate such as a heat shield (7) for a vehicle exhaust system. The rivet (13) comprises a unitary wire mesh structure (19) which has a collar (15) and a shank (17). The collar (15) has a higher density than the shank (17), e.g., the collar (15) has the density of the finished isolator (11). The rivet (13) is formed into the finished isolator (11) by compressing the shank (17) to form a second collar, while restraining the original collar (15) from substantially changing its shape. The rivet (13) can include a metal insert (23) which prevents the wire mesh of the finished isolator (11) from experiencing high levels of compression when the substrate is fastened to its supporting structure.

Abstract: The disclosure provides a monolithic floor for use with a hot slag bucket. The monolithic floor improves the lifespan of the bucket when used with hot slag by reducing warpage caused by heating and cooling and thus significantly reduces the cost of owning and operating the hot slag bucket.

Abstract: “Tinkles” (also known as “gotchas”) (see reference number 20 in FIGS. 1 and 2) are portions of knitted metal loops produced when a tube of knitted wire mesh is cut into individual pieces. In the prior art, tinkles have been considered a fact of life and the approach has been to try to shake them out of the mesh or immobilize them on or in the mesh. By producing a knitted tube (11) having alternating segments (12,13) of knitted rows of yarn and knitted rows of wire, completely tinkle-free knitted socks are produced which are used to produce completely tinkle-free knitted wire mesh filters. Knitted wire mesh filters that cannot release tinkles because they do not have any tinkles can be used in such applications as fuel filters and airbag filters.

Abstract: Expanded metal sheets (5) are used to produce tubular filters (13). The expanded metal sheet (5) has a multiplicity of rows of openings arranged to reduce nesting when the sheet (5) is rolled on itself. In particular, the pitch between the rows of openings, the sizes of the openings, or both the pitch between the rows of openings and the sizes of the openings are varied to reduce nesting when the expanded metal sheet (5) is rolled on itself. The filters (13) can include external circumferential grooves (3), rounded corners (19) produced by a point loading process, textured surfaces (37) between openings, and/or torturous internal paths produced by non-perforated areas of an expanded metal sheet. The expanded metal sheet (5) can be composed of carbon steel coated with a material having a higher heat conductivity, e.g., tin.

Abstract: A wire mesh rivet (13) is provided which is used to produce a wire mesh isolator (11) in a bore (9) of a substrate such as a heat shield (7) for a vehicle exhaust system. The rivet (13) comprises a unitary wire mesh structure (19) which has a collar (15) and a shank (17). The collar (15) has a higher density than the shank (17), e.g., the collar (15) has the density of the finished isolator (11). The rivet (13) is formed into the finished isolator (11) by compressing the shank (17) to form a second collar, while restraining the original collar (15) from substantially changing its shape. The rivet (13) can include a metal insert (23) which prevents the wire mesh of the finished isolator (11) from experiencing high levels of compression when the substrate is fastened to its supporting structure.

Abstract: Expanded metal sheets are used to produce tubular filters. The expanded metal sheet has a multiplicity of rows of openings arranged to reduce nesting when the sheet is rolled on itself. In particular, the pitch between the rows of openings, the sizes of the openings, or both the pitch between the rows of openings and the sizes of the openings are varied to reduce nesting when the expanded metal sheet is rolled on itself. The filters can include external circumferential grooves, rounded corners produced by a point loading process, textured surfaces between openings, and/or torturous internal paths produced by non-perforated areas of an expanded metal sheet. The expanded metal sheet can be composed of carbon steel coated with a material having a higher heat conductivity, e.g., tin. Among other things, the filters can be used in automobile airbag inflators to capture slag and absorb heat produced by the inflator's explosive charge.

Abstract: An improved dipper stick, tool, and thumb combination includes a progressive linkage for connecting the thumb to a thumb actuator wherein the pivot axis of the thumb idler link connection is spaced from the pivot axis of the tool idler link connection. The pivot axis of the thumb idler link connection may be offset outwardly from the inner surface of the dipper stick. A mounting plate may be connected to the inner surface of the dipper stick to locate the pivot axis in the offset position.

Abstract: A substrate such as a heat shield for a vehicle is provided with a unitary compressed wire mesh bushing or isolator formed in place though a bore in the substrate. The bushing is formed by supporting an uncompressed or partially compressed wire mesh sleeve, optionally including a grommet or spacer, on a mandrel positioned within the bore; the mandrel is surrounded on either side of the bore by outer sleeves forming a molding cavity on each side of the substrate, and a slidable tamp is disposed in each outer sleeve and moved towards each other to compress the mesh within the bore and provide the unitary bushing.

Abstract: Hybrid seals (117) are provided which include a metallic component (127) and a flexible, non-metallic, heat resistant component (129), e.g., graphite, which are fully integrated in the finished seal and thus not subject to delamination. The hybrid seals (117) can be produced from hybrid heat resistant strips (107) that can be wrapped into a preform (109) and then compression molded to form the hybrid seal (117). The hybrid strips (107) have a core (111) that comprises a flexible, non-metallic, heat resistant material and a metal mesh (113) knitted around the core. Prior to being formed into a preform (109), the core and the metal mesh are crimped together to begin the process of integrating the metallic and non-metallic components of the seal. The compression molding completes the integration.

Abstract: A wire mesh mist collector pad having multiple density zones, the zones being arranged other than to provide a constantly increasing density gradient, provides a reduced pressure drop and increased capacity. For example, the pad can include at least three zones with the zones arranged so that the density gradient in the direction of gas flow through the pad varies from low to high to low or from high to low to high.

Abstract: A cylindrical wound wire filter with an inner bore, suitable for use with an airbag inflator, has at least two different outer diameters and/or at least two different inner diameters. Wires in adjacent layers can be bonded together by adhesive or brazing, or have a sheet-like material therebetween, such as a ceramic filter paper.

Abstract: A compressed knitted wire mesh article having soft and hard wires, some of which are flat and some of which are round, is used a bushing, seal, seat, bushing, or catalyst support, and is especially useful as an end seal for a catalytic converter. The soft wire can be flat and disposed on the outside to aid it shielding the internal wire from corrosion due to impingement of hot exhaust gasses, and provides increased surface area for better sealing around the catalytic monolith. The hard and soft wires can be co-knit in the same knitting head as alternating wires or in any order, or with one wire wrapped around the other being fed to the knitting needle, or as a striped pattern. The mesh can be textured by precompression, such as crimping between rolls.

Abstract: Expanded metal sheets are used to produce tubular filters. The expanded metal sheet has a multiplicity of rows of openings arranged to reduce nesting when the sheet is rolled on itself. In particular, the pitch between the rows of openings, the sizes of the openings, or both the pitch between the rows of openings and the sizes of the openings are varied to reduce nesting when the expanded metal sheet is rolled on itself. The filters can include external circumferential grooves, rounded corners produced by a point loading process, textured surfaces between openings, and/or torturous internal paths produced by non-perforated areas of an expanded metal sheet. The expanded metal sheet can be composed of carbon steel coated with a material having a higher heat conductivity, e.g., tin. Among other things, the filters can be used in automobile airbag inflators to capture slag and absorb heat produced by the inflator's explosive charge.

Abstract: A compressed wire mesh filter for an airbag assembly has one or more wires wrapped around the outer perimeter of the filter prior to final compression of the mesh to increase the hoop strength of the filter.

Abstract: A compressed wire mesh filter for an airbag assembly has one or more wires wrapped around the outer perimeter of the filter prior to final compression of the mesh to increase the hoop strength of the filter.

Abstract: Two gas conduits of different sizes are connected in a sliding arrangement using a combination of a seal and a bushing, each independently made from knitted wire mesh or wound wire. If a mesh is used, it can be impregnated with a filler, such as mica or graphite, for increased density. Especially useful for vehicle exhaust systems, the arrangement facilitates the use of after-market parts that may have different dimensions than OEM parts. This design slidably connects two gas conduits of different sizes and/or geometries.

Abstract: A compressed wire mesh filter for an airbag assembly has one or more wires wrapped around the outer perimeter of the filter prior to final compression of the mesh to increase the hoop strength of the filter.

Abstract: A wire mesh filter is made from a knitted wire sock, folded along its length, and then wound into a spiral, and is useful for diesel traps and other particulate filters that are regenerable by heating the filter.

Abstract: Annular wire mesh filters for airbag assemblies for passenger vehicles are provided with a series of ribs extending parallel with the axis of the annulus and along the outer wall. The ribs provide added strength to the filter. Also provided is a method of manufacturing the compressed mesh filter with a uniform density, and a molding tool (mold, mandrel, and plunger) for making the compressed mesh articles of this invention.