CA1199822A

CA1199822A - Mesh structure and laminate made therewith

Info

Publication number: CA1199822A
Application number: CA000431855A
Authority: CA
Inventors: Frank B. Mercer
Original assignee: PLG Research Ltd
Current assignee: PLG Research Ltd
Priority date: 1982-07-06
Filing date: 1983-07-05
Publication date: 1986-01-28
Also published as: US4680215A; JPS5993332A; DE3368550D1; US4618385A; GB2124965B; HK67887A; SG33287G; GR79338B; EP0099210A3; ATE24439T1; MY8700547A; ES8502022A1; EP0099210A2; CA1225265B; ES281107U; ES281107Y; JPH0470137B2; ES281106Y; EP0099210B1; ES524275A0

Abstract

MESH STRUCTURE AND LAMINATE MADE THEREWITH.
Abstract In order to produce a biaxially orientated mesh structure using a single axis draw, a plastics material starting material has parallel, side-by-side main zones separated by lines of holes or depressions: the starting material is drawn parallel to the main zones, stretching the main zones into continuous, orientated main strands interconnected by smaller cross-section strands which have been formed from the zones between holes or depressions in each line, and have been orientated at right angles to the direction of drawing by the effect of the main zones decreasing in width as they were stretched. The mesh structure is suitable for cross-lamination.

Description

Background of the Invention The present inventlon relates to a method o~ making a mesh structure.
comprising providing a starting material whic,~ has substantially parallel lines of holes or depressions defining elongate, side-by-side main zones betwe~n the lines of holes or depressions and intermediate zones between the holes or d~pressions in each line, and dr2wins the starting m2terial in a direction substantially parallel to the main zoncs to stretch the startlng material out into a mesh structure lO having orientated main-zones with the orientations therein extending generally parallel to ~he dxawing direction. G8 2 073 O90B discloses such a method, used for making uniaxial.ly-orientated structu~es, and GB 2 035 191B discloses similar starting materials, being stretched in two directions at right angles to fo:rm biaxially-orientated structures. G~ 2 073 090B and G8 2 035 1~18 can also be referred to for background details on stretching and orientating plastics materials.

In the uniaxially stretched materials of GB 2 073 O90B, the p~rts of the main zones which are directly between holes or depressions

2~ stretch out, forming strands interconnecting bars which comprise the remainder of the main zones and also the intermediate zones. In order to obtain biaxial orientation, the structure must be stretched in the direction at right angles, as set out in G8 2 03~ 191A.

U5 3 ~06 073, U5 3 719 540 and US 3 S00 627 disclose products which 1a apparently have main, orientated strands with the orientation therein extending from end to end. In each case, the main strands are intPr-connected at a plurality of positions spaced along the main strands by orientated fibrils which, at least in the case of the first two US Specifications, branch out from the main strands at a small angle.

It is desirable to be able to produce a biaxially-orientated structure with a single direction stretch. The structure so produced should be capable of having two clear axes, substantially at 90 to each other, thcugh this may not oe necessary in all circumstances.
10 Thus it should be possible to have the orientated interconnecting strands substantially at right angles to the main strands, and certainly making a iarge angle to the main strands.

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2 ~ f d ,~

De~ini~ions The term "rectangular" includes square.

The term "orientated" means molecularly orientated.

The te~m "thickness" r~fers to tne dimension normal to -~he plane of the starting materia~ or mesh struc~ure, the term "width" refers to the appropriate dimension in the plane of the starting material or mesh structure (norr,ally at right angles to the direction of the strand in question~, and the term "~:d ratio" is the ratio of the width to 10 the th~ckness.

The "calçula~ed stretch ratio on the interconnecting strands"
is the ratio of the distance apart of the mid-points of the ~ain 20nes after drawing to that before drawing Ithough ,s,~

normally the actual stretch ratio is less due to the main strands necking down sli~htly between connection points with the interconnecti ng strands3.

The width of a main zone is aenerally the distance between S the two lines which are tangent to the line of holes or depressions on either side of the main zone, the same being the case mutatis mutandis for main strands and mesh openings. A somewhat different definition applies to a ribbed structure (see below)l ~ ~ ~ 3 ~

The depressions are not necessarily forme~ by the application of pressureO

The Invention In the method of the invention, the starting material has substantially paral1el lines of holes or depressions defining elongate, side-by-side main .~ones between the lines of holes or depressions and intermediate zones between the holes or depressions in each line. The star~ing ma~erial is drawn in a direction substantially parallel to the main zones while preventing substantial contraction in the direction at right angles to the drawing direction, thereby stretching the main zones out into orientated main strands with the orientation therein extending from end to end and generally parallel to the drawing direction, decreasing the width of the main ~ones when forming the main strands, and simultaneously stretching ~he intermediate zcnes between the main zones in a direction at a large angle to the direc~ion of drawing, whereby, in the mesh structure produced, orientated interconnec~ing strands, formed Frcm ~he intermediate zones, interconnect the main strands, with the orientation in the interconnecting strands extending at a large angle to the main strands.

In the mesh structure of the inYention, there are parallel, orientated ma~n strands whose orientation extends ~9~

from end to end thereof and generally parallel thereto, and orientated, interconnecting strands interconnectins the main strands, the interconnecting strands extending at a large angle to the main strands and having orientation which is directed general1y parallel to the interconnecting strands. The mesh structures can be used to form laminates, particularly cross-laminates with the main strands of one mesh structure layer generally at right angles to the main strands of another mesh structure layer.

~9~3~

In the method of the invention, the main, parallel zones narrow down to form the main strands and thus stretch out the subsi~iary intermediate or transYerse zones into orientated interconnecting strands whose orientation is preferably at right angles to the direction of drawing, and calculated stretch ratios of 5:1 or more can be applied to the interconnecting strands. The orientation of the main strands extends from end to end thereof although they are interconnected by the interconnecting strands at a plurality of positions spaced along the main strands.

It has thus been discovered that a mesh structure which has substantial orientation in two directions at right angles can be produced by stretching a substantiallv unorientated starting material in a single direction. Nonetheless, as explained below, the invention is not restricted to using a single, unidirectional draw.

To facilitate the stretching of the "transverse" zones, these zones should not be too wide (i.e. should not have too great a dimension in the direction in which Lhe main ~ones are stretched) - they are preferably substantially narrower than the .a~

~ain ~ones, e.~. one quarter the width or less, i.e. the distance bet~een the holes or depression of one line and those or the a~ acent line being at least four times the distance apart o, the holes or depressions in any one line. The ma~n strands can have a uniform thickness along their centre line (or another line par~llel to their axes) and their width can also be fairly unifonm. These main strands run right through the mesh structure and 9iV2 the mesh structure its strength. Particularly if the mesh structure is being used for a cross-laid laminatP
(main strands of one mesh structure layer generally at right angles to the main strands of the other mesh structure layer), the transuerse stren~th of the mesh structure is not of impor~ance and ne~d only be sufficient for machine 15 handling in an automatic prosess; thle interconnectin~
strands need only ~o keep the main strands rou~hly parallel prior to laminating. However, it ~s undesirable to stretch ~he main s~rands to such a degree ~ha~ they fibrillate (if thi~ is possible ~ith the particular plastlcs ~ater~al used)~

2~ It is believe~ tha~ if the main ~ones or strands are to exhibi~ suffioient stren~th to orientate the in~ermediate zones9 the interconnecting strands should be of smaller cross-sectional area th~n ~he main strands, and those cross-sectional areas are conveniently measure~ at the mid~p~ints. The maln strands can predominate in weight 9 ~ ? ~

per square unit area of the mesh structure, for Instance for~ing 85, 90, 95~ or even more of the weight of the product, thus ensuring economic use of ~he plastics material.

In order to achieve this, and in order to achieve good crcss-orientation, the dis~ance between the main zones can be small (i.e. the main zones being close together), the holes or depressions (if present) being correspondingly small and forming a very low percentage of the surface area of the starting material. Apart from the foregoing, a small distance between the main zones (~Yhen the main zones are close together) can give yood cross-orientation.
A small percentage width r~duction of the main zones can give a large stretch ratio on the intermediate or transverse zones. The ma~n zones in the starting material are prererably at least two or four times as wide as the distance between -the main zones, if appreciable stretch is to be achieved in the int~rconnecting strands~ There would be a large num5er of the side-by-slde main zones, e.g. at 1east ten and prefera~ly at least fifty or a hundred. Mesh struc~ures can be produced with from fifty to four hundred main strands to'the meter and one would expect mesh structure widths of one to four meters. The main strands ~ill usually be of substantially rectangular section~ i.e. two sides of the rectangle being the faces of the mesh struoture.

If the starting material is to be drawn solely in the transvers2 direction (TD), a stenter can be used. In

3~

~enerai, the holes or depressions in each line should be close tog~ther to achieve the cross orientation of the intenmediate zones - the intermediate zones would thus be small, as measured in the direction in which the star~ing material ~s drawn.

Though one can use a single, unidirectional draw, it may be possible or advantageous to draw ~he s~arting material biaxially. Thus the starting mat rial can be drawn, e.g.
to a small stretrh r~ti~, in the direction at right angles 1~ to the ma~n zones. This drawing will orientate the fntermediate zones to a certain extent, though the orientation need not penetra~e into the sides of the main zones (i.e. pass beyond notional lines on ei~her side nf a respective main zone and tangent to the hsles or depressions~. The stretch 15 rat~o on the interconnectins strands so formed may be for instance 2:1. Subse~uently~ (or even possibly simultaneously~, th~ matPrial i~ drawn parallel to the main zone~, stretching olJt the main zones b!l~ als~ further s~re~ching out the ~n~erconnecting strands in a direct~on parallel to their 20 axes. The whole operat.on could be perforned by giYing a small machine direction (MD) draw us~ng draw rolls and then giv~ng a large TD draw in a stenter.

As a further possibility, once the main strands have been formed, it is poss~ble to draw in the direction at right 25 angles to the main strands9 further to stretch out the ~. 3L 3 ~ ~r Dl ~

interco~necting strands, possibly reducing or eliminating the thicker small zones referred to below.

In general, in the mesh s~ructures of the invention, the ratio of main strand width: transverse pitch of main strands, as measur~d at mid-points ~which are usually the narrowest poin~s) of the main strands, is preferably below 1:5, say from 1:4.5 or 1:4,25 or 1:4 do~n ~o 1:2, though larger relative transverse pitches are possible with suitable dimensisn;ng of the starting material - the main strands at their narrowest points may be separa~ed by a distance of not more than ~hr~e times their ~ dth at thei r narrowest poi nts .

The product~on of the correc~ mesh structure depends upon a combin2tion of var~ous parameters, such as pitching of the holes or depressions (i.e. transverse dlmension o~ the 15 ~ndiv~dual intermediate zones and width of main zones) and draw ratio applied ~o ~he main zonesO The ~ain ~ones in the star~lng material and ~he main strands In l:he mesh s~ructure are preferably much wider than they are th;ck and hence tape-like~ preferred w:d ra~ios for both ~he main zones _ _ ~Q ~nd the main ~trands being at 7east abou~ 5:1, or dt least abou~ 10:19 or a~ least about 2Q:1. If the main zones are not very close together, high w:d ratios are required.
The ac~ual th~ckness, if uniform, may not be o, great importance~
though this has not been A

~ ~7fn~

assessed experimentally. It is found easier to obtain more unifonm thickness strands with very thin starting materials, the thickness normally becoming less unifor~
as the average thickness increases (i,e. less thickness S difference between main strands and the interconnecting strands, and bet~een different zones in the structure);
it is found that starting materia1s of thickness of 0.5mm and less are preferred, the most useful being those of 0.2mm and less. However, in principle, the starting material can be of any suitable thickness.

The preferred starting material is strictly uniplanar, by wh;ch is mean~ that~ ignoring any membrane (which may not lie on the median plane), all par-ts of -the star-ting material are symmetrical about the median plane of the starting material; in this manner, in the mesh structure, all parts ~ill be symmetrical about the median plane, ignoring any membrane~ film or fibri1s (which may not lie on the median p~ane) pxoduced from -the star~ing membrane.
It is further preFerred that ~he starting material should have planar faces apart from the holes or depressions.
However insubstantial departures from uniplanarity or from planarity are no~ excluded - for instance, in an alternative to having starting material with planar faces, it would be possible to proYide the starting material ~S with parallel ribs, which could be formed by direct ext,usion or embossing, the ribs forming the main zones (in this .~

f'~
case9 the width of a main zone is the width of the rib~.

The holes (or depressions if appl icable) can be formed e.g. by punching, slitting, embossing or burning in (on a wat2r-cooled roller), or by fonn~ng them as the starting material itself is formed (for instance obt~rating a slit die e.g. generally as in French Patent Specification No.
368 393 or by integral extrusion of a square mesh as in U~S. Pa~ent Specification No. 3 325 181). Slittin~ is a useful way of fonming the holes as there is no substan~ial 10 material removal and as it enables the main zones to be very close together~ A useful process is that in which a plastics she~t is formed with longi~udinal slits, and is then heated whilst its longltudinal margins are restrained, forming roughly elliptical holes. In general, it is preferred to avoid any s~bstantial protuberance around the periphery of ~he holes or depressions. If depressions are formed, the membrane clGsing the depressions can be ruptured during stretching and the residual film-like material remoYed;
alternatively, an urientated film can remain in the mesh 20 openi ngs .

The starting material is pre~erably not substantially or~entated, though melt-flow orientation can be present.

The s~arting material can be any suitable thennoplastics ~ 3~
material, such as for instance high density polyethylene (HDPE), low density polyethylene, polypropylene, copolymers of HDPE and palypropylene, polyesters, and polya~ide~
Tape-like filaments tend to crack or split ~Ihen produced S from some plastics such as HDPE and polypropylene, but these may be acceptable for certain uses the use of polyes~ers can reduce the tendency to erack or split.
The starting material can haYe a skin on one or both faces containing an ultra-violPt ~tabiliser; if a laminate is formed and the skin is on one face, it would be on the ou~side face~

The intermedi~te zones are stretched (and hence usually the axes and direction of orientation of ~he interconnecting strands will extend) at a targe angle to the direction Of drawing the starting material; this angle is preferably roughly ~0, bu~ the angle could be substantially less than 90 though it is preferably more than 75. Thus, though the lnterconnectin~ strands preferably extend substanti~lly at r~ght angl~s to the main s~rands, this need not be 20 so; the ~nterconnecting strands need not have any specific geometrical shape nor be aligned with any interconnecting strand on the o~her side o~ the respective main strand - for instance, the interconnecting strands could form the ~Iverticals~ in a "brick wall" pattern with the main strands forming the "hori~ontals".

~ .

The mesh structure can be very flat and thus easily laminated to provide good cross-laid lamina~es. Although there may be small zones of thic~er and unorientated or less orientated material where the interconnecting strands S Join th~ main sl:rands, there need be no large-sized n~dules which could interfere with bonding. The struc-ture may be cross-laminated with a sirnilar or identical struc-ture, but this is not necessarily so. The 10 structures can be bonded direc-tly face to face or can be separated by a-t least on~ further layer.

Tbe mesh structure of this invention can have a high strength in the direction of the main strands and thus the cross-laid 15 laminate will have good strength char~cteristics in two directions at right angles. As the mesh structure of the invention can be formed and laminated at much ~reater speeds than fabrlcs can be woven or knitted, the invention renders possible the fabrication at relatively high speeds 20 of a material which can be substituted f~r woven fabrics for some purposes.

The mesh structure of this invention can be used without lamination, i.e. as an unlaminated material.

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Description of Preferred Embodiments The inventiofl will be further described~ by way of example, with reference to the accompanying drawin~s, in which:-figure 1 is a plan view of a plastics star~ing material 5 for forming a mesh struc~ure in accordance with the invention;

Fisure 2 is a plan view of the mesh structure formed ~herefrom;

Figures 3 and 4 are plan views of two further mesh structuresin accordance with the invention;

Figure 5 is a perspectiYe view of the mesh structure of 10 Figure 4;

Figure 6 is a section along ~he plane YI-YI in Figure Figure 7 shows Yarious shapes of holes or depressions that can be used in the s~art~ng material;

Figure 8 ~s a schematic perspective view of a lam~nate in ~ccordance with the lnvention; and Figures 9 to 14 are schematic sections through six other lamindtes in accordance with the inventionO

~) 3 ~ F~ t In the drawings, the hatchings run up and down the slope: only sample contoured zones are indicated with hatchings.

Fiqures 1 to 5 Looking at Figure 1, the starting material is a strictly uniplanar sheet of plastics material 1 having planar faces and in which is formed a regular pat~ern of holes or depressions 2; the holes or depressions 2 are in lines, the holes or depressions 2 in each line dividing the starting material 1 into a large number of parallel main zones 3 which are close ~ogether and on either side of or separated by the lines of holes or depressions 2:
the holes or depressions 2 also define small transverse or intermediate zones 5 between the main zones 3 and lS bet~een the holes or depressions 2: each of the intermediate zones 5 is symmetrical about a respective line at right angles to the line of holes or depression6 2, and the interconnecting strands 6 are at right angles to the main strands 4: as the starting material is uniplanar with planar faces, the thickness of each intermediate zone 5 is the same as that of the main zones 3. i.e the intermediate zones S are defined between the planes defined by the outer faces of the main zones: Che holes or depressions 2 are close 2~ together and the distance between the holes or depressions 2 of one line and those Oe the adjacent line is substan~ially greater than the distance aeart of the holes or depressions 2 in each line; the holes or depressions 2 prefe~ably have their cen~res on a notional rectangular grid and the area of the holes or depcessions 2 is prreferably less than 203 of the plan view of the starting mate~ial 1. Por the purposes of illustration and for most of the following ~xamples, the holes or depressions 2 are shown as circular, but Figure 7 shows various shapes for the holes or depressions 2, including simple piercings and slits. Although circular holes or depressions are easier for tooling, it is suggested that square holes on the square, with radiussed corners (Figure 7, middle of top row) give better control during stretching and a becter, more regular product - "on the square" means that the sides lS o~ the sguare are parallel to and at right angles to the stretching direction. If elongated, the direction in which the major axis of ~he hole or depression 2 extends can be either parallel to the lines of holes or depressions 2 or at right angles thereto.

2~ I'he starting material l is drawn only in the direction indicated by the double arrow in Figure 1, while preventing any substantial contraction of the web of material as a whole in the direction at right angles to ~he drawing direction, i.e while preventing any substantial reduction of the ttransverse) pitch of the main Zones 3, though permitting reduction in Width of each individual main zone 3. As illustrated in Figure 2, the ~aterial forms a geometrically regular product.

The main zones 3 in the starting material l are ~,J

,~

f~

17 a stretched out into continuous, uniaxially-orientated, rectangular section main strands 4 which are like tapes or filaments running right through the st~ucture, their orientation extending longitudinally thereo, i.e.
S generally parallel to the drawing direction, and from end to end thereof, and their centre lines have substantially uniform thickness. At the same time, the width of the main zones 3 substantially decreases, whereby the force of contraction of each main strand 4 as the main strand 4 reduces in width causes the intermediate zones 5 to stretch at right angles to the drawing direction, to foLm discontinuous, smaller cross-sectional area, uniaxially-orientated, transverse, interconnecting strands 6 which extend at right angles lS to the main strands 4 and interconnect the main strands

4 at a plurality or large number of positions spaced along the main strands 4, with the orientation extending longitudinally of the interconnecting strands 6, i.e. at right angles to the drawing direction. The mesh structure is biaxially-orientated. In the generally cectangular mesh openings foLmed, the largest dimension parallel to the main strands 4 is substantially greater than that at right angles to the main strands 4. The width o the interconnecting strands 6 is su~stantially ~5 less than that of the main strands 4 and the cross-sectional area of the mid-points of the interconnec~ing strands 6 i5 less than the minimum cross-sectional ared of the main strands 4: the orienta~ion of (oc stretch catio applied to) the interconnecting strands 6 may be ~i z~

substantially more than ~ha~ applied to the main strands 4, thoush this is not essential~ The stretch ratio of the interconnecting strands 6 is determined by the diameter or width of ~he holes or depressions 2 and the reduction in width of the main zones 3 when forming the main strands 4.. The main zones 3 should decrease in width by at least 50~, as ~easured at their narrowest parts. According ko the stretch ratio applied, small thicker zones 7 ~smal7 ;,~ blobs and/or unstretched shoulders ~) may remain a~ acent each end of each interconnectinq strand 6. The zones 7 may be thicker than both the main and interconnecting strands 4~6, or just thicker than the main strands 4.
The zones 7 need not necessarily be present; for instance with polyes~er, the corresponding ~ones may be ~ at or hav~ slight depress~ons~ indicat~ng that biaxial orientation has occurred in such zones ~th~s possi~ly occurs even if there are blobs or shoulders ~. No aceount is taken herein or the small zones 7~ or of the depressionsl when giving the stretch ratios on the interconnecting strands ~0 69 i.e. ~ is assumed tha~ the whole of each interconnecting strand 6 stretched out unifor~ly, although this may not be ~he case.

The s~retching is carried out at a temperature above the second order transition temperature of the plastics material but swbstantially below the softening point so that melt ~low orientation is avoided during the stretching; for example for HDPE, the preferred temperature range is 75.

.

fP~

lg ~o 102C. After stretching, the structures can be annealed in a well known manner.

Fi gure 7 As Indicated above, Figure 7 shows various shapes of holes or depressions 2 that can be used in the starting material.

Examples To provlde typical examples9 a parallel-faced starting material was formed with holes on a notional rectangular yrid. The square holes of Example 4 were "on the square".

The starting material was stretched a~ an elevated temperature.
The followiny Table g;ves detalls of four Examples. All dlmenslons are in mm9 unless otherwise specified~ The startlng material was planar and effectively parallel ided, though differences in thickness were noted in one - 15 starting material (used for Examples 1 and 2)3 the maximum an~ minimum thickness of the starting msterlal being recorded as 0.28 and 0.21 rmn (nominal 0.~5 mm). In each Example, 3 ~
the maximum thickness of the produc~ was atr~e~ 7.
".,,. " .
I)ue to thickness variations in the start;ng materials (small in the case of Examples 3 and 4), there were variations in the d~mensions observed in the products, but average Yalues have been recorded for Examples 1 and 2 and ~r.

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typical values for Examples 3 and 4. In commercial production, closer thickness tolerances would be required of the starting material than those indicated for Examples 1 and 2.

T_ .
Ex~l e 1 2 3 figJre in ~hich illustra~ 2 3 4 4 Ma~erial ~0/20 H [PE/L ~. * H [~E H IP~
Thic~cr~ss 0.2~ 0.5 4.S
Hole ~ape cir~larcirallar cir~ular sc~are, radi ussed corr~
Hcle si2 1.6 3.175 1.6 6.~5 0 .75 ~dius con~r~
Hol e pi tch (s~etch direction) 2.4 4.7 2.4 8 Hole pi~h ~ )6.36 12.7 12.7 25.4 w: d ratio nsin zDnes 19: 1 38:1 Z:l 4.2:1 Distance apart of holes (stretch 008 1.525 0.8 1.65 direction)- x Distances apart of holes (transverse) 4.76 9.525 ll.l 19.05 _ y y/x 5.95 6.25 13.9 11.5 T~era'are of Stret~ C~ 75 85 75 85 90 S6 Stretch ra'cio on 1 or~itudir~l strar~ls 7:1 3.5:1 9:1 ~.6:1 Longi~dinal s~and wid~ ~duction 66~ 385 44~ 5 tnE~sured at mi~point) measured in trans~er~e 4.g 7.2 6.5 15.5 di r~ion Cdl~ldted stretx:h ratio on i"~ ing 3.C3:1 2.26:1 4.05:1 2.58:1 strar~s Longitu~ina1 strand thi~ness (mi~p;~int= 0.~3 0.07 0.16 1.78 thirrest point) Lor~ntudinal strard width 1 5 5.5 6.2 9.0 (mid~in~nam7Ae~ par~) - a w:d ratio longitudinal s~a~l19:1 79:1 ~9:1 5:1 strar~ ræss 0.08 0.07 0.20 2.5 (mi~point) .ou~ rarld 0 3 0.3 0.5 1.0 wldth (nn~poin~
Thickness of ~i~est po1nt of stn~ 0.18 0.18 0.45 3.3 a/b 5 1~.3 12.4 9 '~ Co-extrJsion (one-sided) ** Closest F'igure Figure 8 A cross-laid laminate is shown in Figure 8, and can be considered as haYing been made in a machine whose machine direstion (MD) is indicated by the arrow. The laminate is formed of two layers 21, 22, each of which can be generally ~n accordance with any of Figures 2, 3, or 4. The top layer 22 has been stretched in the MD and the bottom layer 21 has been stretched in the transverse direction iTD).

The bondin~ Is preferably effected by providing a multi-component startin~ material, having on at least one face a bonding material which bonds a~ a ~emperature which does not destroy the physical properties of the mesh strucf:ure, ~he two ~esh struct~re layers being heated to bond them - thus he bondiny material can be a skin which melts or becomes tac~y at a temperature (or temperature and pressure~ at whkh ~he main component of the mesh structure would not de-orientate. The bonding mater~al may b~ for instance ethylene vinyl acetate or low densi~y polyethylene (LDPE);
the starl:ing ~ater~al can for instance be llnorientated ., 0.15mm ~hick polypropylene ~i~h a thin layer of LDPE on at leas~ one face. The bonding matQrial c2n be provided ln any suitable way, for instance by ex~rusion coating or co-extrusion. Alternatively, a bonding material or adhesive can be applied imme~ately prior to laminating.

Figures 9 to 14 In Figures 9 to 14 MD stretc~ed layers are indicated as 21 and TD stretched layers are indicated as 22, although in the alternative these could be reversedO Figures 9 and lQ iilustrate three-layer and four-layer laminates respectively. Fi~ures 11 to 13 show the incorporation of sne or more layers 23 of anothe!r material, e.g. polyethylene f~lm. Figure 14 shows the laminal:ion of a layer which can be generally in accordance with Figure 2, 3 or 4, with a film 23 of plastics material, e.g. polyethylene ~ilm~ which has a preferred or single direction of or~entation (direction of m2ximum strength) at right angles to the main strands 4.

U_ The s~ngle layer mesh structure of the invention can be used for: Sunshade cloth, wind-breaks, sand barriers (small in ~r /A~
thic~nesses), civ~l cn~ " ;ng such as ground stabilisation ~9 or reintorcement (large thicknesses), general cons~ruction, such as concrete reinforcemen~, plaster reinforcement for ceiling panels or as a false ceiling, and asphalt reinforcement with ~he main strands extending transversely of the traffic direction (in this case, polyester is a preferred ~aterial).

The laminate of ~he invention can be used for or as an alternative to:

Textile fabrics for industrial app7ication, wind-breaks, shade cloths, bases for needle ~elt, olive harvesting ~ets, pac~agin~, tarpaulin, bale wraps, carpet backin~s, or sacks or bags e.g. for wool, cement (laminated with paper or film) or fertilizers.

Claims

The embodiments of the invention in which an exclusive property or privilege is claimed are defined as follows:-

1. A method of making a plastics material mesh structure, comprising:
providing a plastics starting material which has a regular pattern of holes or depressions, the holes or depressions being in parallel notional lines, the distance between the holes or depressions of one line and those of the adjacent line being substantially greater than the distance between the holes or depressions in each line, the holes or depressions defining elongate, side-by-side main zones between the lines of holes or depressions and intermediate zones between the holes or depressions in each line, each of which intermediate zones is generally symmetrical about a respective notional line at right angles to the line of holes or depressions the major part of the thickness of each intermediate zone being between planes defined by the outer faces of the main zones; and drawing the starting material only in a direction substantially parallel to the main zones while preventing substantial reduction of the pitch of the main zones though permitting reduction in width of each individual main zone, thereby stretching the main zones out into continuous, substantially uniaxially-orientated main strands with the orientation therein extending substantially uniformly from end to end and generally parallel to the drawing direction, substantially decreasing the width of the main zones when forming the main strands whereby the force of contraction of each main strand as the main strand reduces in width causes said intermediate zones to stretch in a direction generally at right angles to the drawing direction to form discontinuous, substantially uniaxially-orientated interconnecting strands which interconnect the main strands, whereby a biaxially-orientated mesh structure is produced comprising said orientated main strands and said orientated interconnecting strands with the orientation in the interconnecting strands extending generally at right angles to the main strands and the cross-sectional area of the mid-points of the interconnecting strands being less than the minimum cross-sectional area of the main strands.

2. A method of making a plastics material mesh structure, comprising:
providing a plastics starting material which has a regular pattern of holes or depressions, the holes or depressions being in parallel notional lines, the distance between the holes or depressions of one line and those of the adjacent line being at least four times the distance between the holes or depressions in each line, the holes or depressions defining elongate, side-by-side main zones between the lines of holes or depressions and intermediate zones between the holes or depressions in each line, each of which intermediate zones is generally symmetrical about a respective notional line at right angles to the line of holes or depressions, the major part of the thickness of each intermediate zone being between planes defined by the outer faces of the main zones, and drawing the starting material only in a direction substantially parallel to the main zones while preventing substantial reduction of the pitch of the main zones though permitting reduction in width of each individual main zone, thereby stretching the main zones out into continuous, substantially uniaxially-orientated main strands with the orientation therein extending substantially uniformly from end to end and generally parallel to the drawing direction, substantially decreasing the width of the main zones when forming the main strands whereby the force of contraction of each main strand as the main strand reduces in width causes said intermediate zones to stretch in a direction generally at right angles to the drawing direction to form discontinuous, substantially uniaxially-orientated interconnecting strands which interconnect the main strands, whereby d biaxially-orientated mesh structure is produced comprising said orientated main strands and said orientated interconnecting strands with the orientation in the interconnecting strands extending generally at right angles to the main strands and the cross-sectional area of the mid-points of the interconnecting strands being less than the minimum cross-sectional area of the main strands, and in which mesh structure there is adjacent each end of each interconnecting strand a zone of plastics material which is thicker than the material of the remainder of the interconnecting strand.

3. The method of Claim 1 or 2, wherein the starting material is substantially unorientated.

4. The method of Claim 1 or 2, wherein a substantially unorientated starting material is subjected to a small stretch in d direction at right angles to said drawing direction, prior to drawing the starting material in said drawing direction.

5. The method of Claim 1 or 2, wherein, after drawing the starting material in said drawing direction, the mesh structure is drawn in a direction at right angles to said drawing direction.

6. The method of Claim 1 or 2, wherein the main zones are substantially wiser than they are thick.

7. The method of Claim 1 or 2, wherein the main zones are generally rectangular in shape, as seen in section normal to said drawing direction, being substantially wider than they are thick.

8. The method of Claim 1 or 2, wherein the ratio of the width to thickness of the main zones is about 5:1 or more.

9. The method of Claim 1 or 2, wherein the ratio of the width to thickness of the main zones is about 20:1 or more.

10. The method of Claim 1 or 2, wherein said holes or depressions are on a notional rectangular grid.

11. The method of Claim 1, wherein, in the mesh structure formed, there is adjacent each end of each interconnecting strand a zone of plastics material which is thicker than the material of the remainder of the interconnecting strand

12. The method of Claim 2 or 11, wherein said thicker zones are at least about 1.32 times as thick as the thickness of the mid-point of the interconnecting strands.

13. The method of Claim 2 or 11, wherein said thicker zones are at least about 1.85 times as thick as the thinnest part of the main strands.

14. The method of Claim 1 or 11, wherein the distance between the holes or depressions of one line and those of the adjacent line is at least about 2.975 times the distance between the holes or depressions in each line.

15. The method of Claim 1, 2 or 11, wherein the thickness of the starting material is about 0.5 mm or less.

16. The method of Claim 1, 2 or 11, wherein the product of the distance between the holes or depressions of one line and those of the adjacent line and the overall stretch ratio applied, divided by the width of the holes or depressions as measured in the direction at right angles to said drawing direction, is at least about 10.5.

17. The method of Claim 1, 2 or 11, wherein the pitch of the main strands in the direction at right angles to said drawing direction is less than about five times the width of the main strand at its narrowest part.

18. The method of Claim 1, 2 or 11, wherein the main strands and the interconnecting strands define substantially rectangular mesh openings whose dimension.
parallel to the main strands is substantially greater than their dimension parallel to the interconnecting strands.

19. The method of Claim 1, 2 or 11, wherein in said mesh structure the main strands contain at least 85% of said plastics material of said mesh structure.

20. The method of Claim 1, 2 or 11, wherein the main strands have substantially uniform thickness, as seen in section along their centre lines.