Description:Form 2
The Patent Act 1970
(39 of 1970)
&
The Patent Rules 2003

Complete Specification
(See section 10 and rule 13)

Title of the Invention:
SYSTEM & PROCESS OF PRODUCING
INTERLACED JOINT-FREE ARRAY OF LINKS
Applicant: Sunjewels Private Limited
Nationality: Indian
Address: 605-606, Multistoried Building, SEEPZ,
Andheri East, Mumbai – 400096,
Maharashtra, INDIA

The following specification particularly describes the invention and the manner in which it is to be performed.

FIELD OF THE INVENTION
The present invention relates to a process to produce jointless chain. Particularly, the invention relates to process to produce chain of high quality and precision with for jewelry and ornamental application. More particularly, the process is suited to metals of higher rigidity than conventional noble metals.

BACKGROUND OF THE INVENTION
Jewelry manufacturing has the challenge of aesthetics and finish besides robustness and other manufacturing issues. The processes used are by and large same as those used for any metal work of intricate shape. Investment casting is one of the most common techniques deployed for jewelry manufacture in volumes. US Patent 1398706 describes this.
Jewelry products like Chains and continuous links need to be assembled by interlinking and joints are detrimental here again. Several prior arts describe such processes which involve multiple mechanical operations and skill.
US895649 discloses a system of dies by means of which a chain of the link type may be punched or stamped out from a bar of cruciform steel, the dies being so arranged that the links are formed successively as the bar is fed through them, independent dies being arranged to form links from the two blades of the steel, while an additional die is adapted to remove the stock connecting the links, thereby separating them into a plurality of independent, connected, weldless links.
Jewelry and ornaments including chains ought to have an external finish unparalleled by other metallic objects. Joints of any kind significantly compromise on this aspect. Metals other than precious and noble metals are no longer a must criteria if the external finish creates an awe. Without exaggeration, even black jewelry is beautiful if it has “rich” looks!
Present invention addresses such growing need effectively.

OBJECTIVE OF INVENTION
The objective is to invent a process to produce interlaced joint-free chain or array of links.
Another objective is to invent a continuous process of producing array of links or chain from a rod.
Another objective is to invent a process of producing array of links or chain with high and consistent finish.
Yet another objective is to invent a process of producing jointless chain or array of links which has unconventional appearance.
Another objective is to invent a process of producing array of interlaced links or chain with high durability.

SUMMARY OF INVENTION
A three-axis co-ordinate arrangement is referred to facilitate visualization of relative movement of parts during a machining process of the present invention.
The system and the corresponding process of producing a joint-free array of links uses a slender rod, of illustratively 3 meters length, as an input material or simply input, which is converted to an array of intra-woven joint-free array links by the present invention. The slender rod is progressively moved forward, rotated, as well as moved back and forth to be able to machine the entire length of the rod into the array of links of a prescribed link shape or combinations of several prescribed shapes. The slender rod is moved via a precision control unit executing a computer program to drive an automated feed set-up, along a Z-axis, while the slender rod can also likewise be configured to rotate around the Z-axis, both in a clockwise as well as an anti-clockwise direction with precision. All linear and rotational movements of the input material are steered through the automated feed set-up governed by the precision control unit, in synchronism with a plurality of cutting tools disposed in a machining console. The automated feed set-up is configured for loading a plurality of slender rods at a time and feeds in one slender rod at a time to the machining console. A complete length of the slender rod is converted into the interlaced joint-less array of links in a continuous process. The slender rod is a uniform circular cylinder in the preferred embodiment but not limited thereto.
The machining console comprising a plurality of horizontal cutting tools with rectilinear movement at least in an X-axis, and rectilinear movement in a Y-axis, coupled with rotational freedom around the X-axis, works in synchronism with the automated feed set-up. All linear and angular movements are controllable by the precision control unit to an accuracy or a least count of the order of few microns to few hundred microns.
To be able to prudently develop a machining program for and as per the present invention, a machining segment of an array of links is calculated. The machining segment is an operational length of the slender rod which corresponds to a repeatable programming sub-routine for machining the slender rod. The machining segment comprises at least a unit length which is a linear dimension of each link of the array of links or chain being described as a preferred embodiment. Further, the machining segment takes into account two partial lengths of links on either side of a complete link considering an inter-link gap in-between different links. Importantly, for providing maximum cutting access within two adjacent links corresponding to a largest feasible cutting tool , an intra-link gap is worked out.
The machining segment is machined in a preferred sequence and one of the infinitely possible different machining sequence is based on a virtual machining division of the machining segment in four divisions.
Alternate links are machined orthogonal to corresponding links. The present invention is NOT limited to identical links and links of different sizes and shapes and combinations thereof are producible by the series of inventive material removing sequence executed by the machining console which is computerized numerically controlled (CNC).
A first end of the slender rod is moved into the machining zone of the machining console so that somewhat more than the machining segment of slender rod is clearly accessible in the machining zone of the machining console. In the machining zone, the plurality of cutting tools cut and remove the rod material axially as well as radially, as programmed. The slender rod is stripped of rod material in several identified sectors in a division wise prescribed order, to minimize movement and changing of cutting tools. Each machining sector is further stripped of rod material to either be suitable for a vertically oriented links form or a horizontally oriented link form. To be appreciated that in reality, all links have flexibility and freedom of movement desired in any chain or array of links, particularly of adornment, and the concept of the vertically oriented links form and the horizontally oriented link form is an inventive concept of machining and keeping each link in a prescribed orientation, till they are physically separated from one another. The rod material is removed considering the slender rod in position relative to these orientations.
Significant locations of rod material removal include
- Within a vertically oriented link form
- Within a horizontally oriented link form
- The inter-link gap, that is between and end of a link form and a beginning of another link form
The essence of the present inventive process is to carve out the horizontally oriented link form in-between two vertically oriented link forms, and likewise carve out the vertically oriented link form in-between two horizontally oriented link forms, thus termed interlaced; and thereby altogether avoid a “joint” in any link. Term “link form” is used for incompletely machined links.
Noteworthy that vertical and horizontal orientations are only relatable to intra-link forms since each link form or link is vertical and horizontal or inclined during machining as well as subsequent process and use. In different words, “vertically oriented” could be replaced with “firstly oriented” and “horizontally oriented” could be replaced with “secondly oriented”. Crudely, in the preferred embodiment with a horizontal machining center, the links are generally machined while in a vertical form and therefore such nomenclature should not be construed to limit the invention.
Between each vertically oriented link form and horizontally oriented link form, that is, the intra-link gap, the rod material is removed after discretely rotating the slender rod to an inclined position wrt the cutting tool such that at least a minimal joining bridge is consciously retained between each end of the horizontally oriented link forms and the vertically oriented link forms. This joining bridge is crucial so that the just completed horizontally as well as vertically links forms continue to remain in a straight line in the Z-axis. In absence of consciously maintaining such joining bridges, the respective links would start drooping as the rod material retained as the joining bridge tends to disappear by continuing machining, and would aggravate in the influence of gravity and machining vibrations. Such an undesired situation would imply uncontrolled movement of link forms and would adversely impact machining process resulting into less than perfect machining!
The joining bridge has extra-thin ends on either side of varying appearance depending on corresponding shape of individual link, illustratively alternative forms of arrays of links. The shape and numbers of the joining bridge(s) is immaterial as it meets two objectives:
1. To hold all links against one another even after completing machining action on the machining console
2. To be able to break like a “biscuit” or a “cookie” to reduce a handling volume of the machined yet unfinished chain or array of links (180).
The rod material of the joining bridge and the extra-thin ends are eliminated by a combination of a plurality of compatible supplementary processes.
To pre-empt undesired biscuit-like breaking and thereby drooping of machined links the machined links with joining bridge nearest to the under-machining links are provided with a dynamic anti-gravity support arrangement. This dynamic anti-gravity support arrangement, while avoiding gravitational fall has to be non-interfering with the forward, back and forth z-axis movement of the slender rod. The anti-gravity support arrangement is a mechanical arrangement. Alternatively, this is a contact-less arrangement including an electro-magnetic arrangement. Illustratively, levitation can be deployed to achieve a suspension like arrangement.
To ensure that the minimum joining material is indeed technologically minimal, an analysis of
- Diameter, hardness and machinability of the raw material, and
- Compatible cutting tool of optimum strength and minimum diameter
is done. A rotational speed and rate of depth feed of the cutting tool is then worked out which would provide machined outcome with optimum surface finish.
Illustratively, a 3mm diameter titanium rod would be machined by a cutting tool of narrower diameter and at a lesser cutting speed, while a 6mm diameter titanium rod would be machined relatively faster.
A machined array of links obtained from the machining console is joint-less. Machining of each link is with high precision and surface quality. It is known that precision machining may lead to sharp edges between non-coplanar surface, besides the intentionally retained joining bridge and the extra-thin ends, and therefore the plurality of compatible supplementary processes as below described is deployed to produce a useable product, produced more economically than finer machining!
Following compatible supplementary processes are deployed in the preferred embodiment the present inventive process of producing joint-less array of links:
Contours smoothening:- By minimal use of diamond files, micro-grinding wheels, abrasive papers the machined array of links is smoothened around rough edges and contours, and exposed surfaces, without significant material removal, besides clearing the joining bridges and the extra-thin ends.
Ultrasonic Cleaning:-
The machined array of links are placed in a cleansing solution and subjected to ultrasonic vibrations, thereby agitating the cleansing solution fluid and caressingly clean all surfaces including hard-to-reach surfaces due to the entangled construction. Noteworthy that such ultrasonic vibratory cleaning would not be worthwhile in links produced individually, particularly since those links undergo messy joining and assembly process and cleaning with such delicacy is ineffective as well as wasteful.
Identification and traceability:- Towards effective marketing including traceability of such a premium possession of users, embossing by a stamping die is incorporated on identified links, without compromising on aesthetics.
Surface preparation:- Matte finish in itself is a valuable addition in appeal of premium products. Furthermore, a matte surface is a prudent preparation for further surface enhancements. The present process incorporates a controlled propulsion process of abrasive particles at controlled speeds and orientation, that removes any surface imperfections and improves the adhesion of any coatings or finishes/finishing process applied later.
Two-step Blackening:-
- A first blackening process comprises heating the machined array of links (180) in a furnace at 430°C - 530°C for 7 to 15 minutes, when the heat and temperature causes following controlled oxidation reactions:
• Titanium: Ti (s) + O₂ (g) → TiO₂ (s) (Titanium Dioxide)
• Zirconium: Zr (s) + O₂ (g) → ZrO₂ (s) (Zirconium Dioxide)
Oxide layers thus formed are black and ceramic-like, which darkens the surface of the links, enhancing their aesthetic appeal and corrosion resistance.
- Blackening at this stage provides a durable finish that lasts longer in various environments.
-Annealing at room temperature ensures the material bonds well with base surface of links and retains its strength and stability.
-A second blackening process is similar to the first, to form a second protective layer.
This double blackening enhances the depth and durability of the blackened finish. It also provides an additional layer of protection against wear and corrosion.
Polishing and lustering:- Done using blue and white luster compounds, providing a mirror-like shine to the surface.
Noteworthy, that some of the above supplementary processes would fail to result into comparable enhancement in finish and appeal since links with joints of any nature and technology including soldering etc. cannot have a base surface as smooth as a joint-free surface producible by the present inventive process and therefore even after deployment of such processes, the end product fails to match joint-less chains producible by the present process.
It implies an array of assorted links is most economically producible through the present invention with a corresponding machining segment calculation and a respective programming sub-routine for such array of links of assorted links. In such requirement the inter-link gap and the intra-link gap is a summation of corresponding shape and contour of the link on either side. Such a prudent programming application is a significant enhancement to machining capability of such systems with NIL investment in manufacturing infra-structure.

BRIEF DESCRIPTION OF DRAWINGS
Figure 1-3, 6 is a perspective view of a system and its constituents as per present invention.
Figure 4-5 are block diagrams of the system and process of the present invention.
Figure 7-11 are front views of array of chain and its machining aspects as per present system and process.
Figures 12-20 are perspective views of machining process.
Figures 21-24 are perspective views of two embodiments of a joining bridge.
Figure 25-26 are generic views of different arrays of chains.

DETAILED DESCRIPTION OF INVENTION
The preferred embodiment of a system (100) and a corresponding process (200) of producing interlaced joint-free array of links (180) or chain as per our invention is now being described with the help of drawings. It is to be noted that virtually unlimited number of shapes and combinations thereof can be created using the concept of this product and process with insignificant incremental cost; and therefore no shape and material described here is to be misconstrued as limiting this invention.
A three-axis co-ordinate arrangement is referred throughout this description, as seen in Figure 1 and subsequently, to facilitate visualization of relative movement of parts during a machining process of the present invention.
Figures 1-5, the system (100) and the corresponding process (200) of producing a joint-free array of links (180) uses a slender rod (140), of illustratively 3 meters length, as an input material or simply input, which is converted to an array of intra-woven joint-free array links (180) by the present invention. The slender rod (140) is progressively moved forward, rotated, as well as moved back and forth to be able to machine the entire length of the rod into the array of links of a prescribed link shape or combinations of several prescribed shapes. The slender rod (140) is moved via a precision control unit (125) executing a computer program to drive an automated feed set-up (105), along a Z-axis, while the slender rod (140) can also likewise be configured to rotate around the Z-axis, both in a clockwise as well as an anti-clockwise direction with precision. All linear and rotational movements of the input material are steered through the automated feed set-up (105) governed by the precision control unit (125), in synchronism with a plurality of cutting tools (120) disposed in a machining console (115). The automated feed set-up (105) is configured for loading a plurality of slender rods (140) at a time and feeds in one slender rod (140) at a time to the machining console (115). A complete length of the slender rod (140) is converted into the interlaced joint-less array of links (180) in a continuous process. The present invention is NOT limited by the length of the slender rod (140), and as a variation the input material can be a roll of slender rod (140) with a straightening attachment, disposed before the automated feed set-up (105) that feeds input material to the machining console (115). The straightening arrangement may be required in order to remove any residual curviness owing to a roll formation of the input material by uncoiling, and is not described in further details in order to remain focused on inventive machining aspect of the present invention.
The slender rod (140) is a uniform circular cylinder in the preferred embodiment but not limited thereto.
The machining console (115) comprising a plurality of horizontal cutting tools (120) with rectilinear movement at least in an X-axis, and rectilinear movement in a Y-axis, coupled with rotational freedom around the X-axis, works in synchronism with the automated feed set-up. All linear and angular movements are controllable by the precision control unit to an accuracy or a least count of the order of few microns to few hundred microns.
A continuously serially interlaced joint-less chain (180) is produced by a series of inventive material removing sequence using machining steps as elaborated below.
Figures 7 - 11 show a generic shape of the array of links (180) used to describe the production process of the preferred embodiment. To be able to prudently develop a machining program for and as per the present invention, a machining segment (147) of an array (180) is calculated. The machining segment (147) is an operational length of the slender rod (140) which corresponds to a repeatable programming sub-routine for machining the slender rod (140). The machining segment (147) comprises at least a unit length (144) which is a linear dimension of each link of the array of links (180) or chain being described as a preferred embodiment. Further, the machining segment (147) takes into account two partial lengths of links (160) on either side of a complete link (160) considering an inter-link gap (145) in-between different links (160). The partial length is at least a half-length of the link (160). Importantly, for providing maximum cutting access withing two adjacent links corresponding to a largest feasible cutting tool , an intra-link gap (146) is worked out. The significance of the intra-gap link (146) would be clearer in further description.
The machining segment (147) is machined in a preferred sequence and one of the infinitely possible different machining sequence is based on a virtual machining division of the machining segment (147) in four divisions – a first division (141a), a second division (41b), a third division (141c) and a fourth division (141d).
Alternate links (160), for example, link numbered 1, 3,…, (N-2), N are machined orthogonal to corresponding links (160) numbered 2,…., (N-2). However, The present invention is NOT limited to identical links and assorted profile of links (160a, 160b, 160c, 160d), Figure 25, 26, of different sizes and shapes and combinations thereof are producible by the series of inventive material removing sequence executed by the machining console (115) which is computerized numerically controlled.
Figure 12, 13, a first end of the slender rod (140) is moved into the machining zone (150) of the machining console (115) so that somewhat more than the machining segment (147) of slender rod (140) is clearly accessible in the machining zone (150) of the machining console (115). In the machining zone (150), the plurality of cutting tools (120) cut and remove the rod material axially as well as radially, as programmed.
Next, Figure 14, the slender rod (140) is stripped of rod material in several identified sectors (142) as illustratively shown hatched, however sequentially in the first division (141a), the second division (41b), the third division (141c) and the fourth division (141d) in order to minimize movement and changing of cutting tools (120).
Figure 15-19, each machining sector (147) is further stripped of rod material to either be suitable for a vertically oriented links form (151) or a horizontally oriented link form (152). To be appreciated that in reality, all links (160) have flexibility and freedom of movement desired in any chain or array of links, particularly of adornment, and the concept of the vertically oriented links form (151) and the horizontally oriented link form (152) is an inventive concept of machining and keeping each link in a prescribed orientation, till they are physically separated from one another. The rod material is removed considering the slender rod (140) in position relative to these orientations.
Significant locations of rod material removal include
- Within a vertically oriented link form (151)
- Within a horizontally oriented link form (152)
- The inter-link gap, that is between and end of a link form (152, 152) and a beginning of another link form (151, 152)
The essence of the present inventive process is to carve out the horizontally oriented link form (152) in-between two vertically oriented link forms (151), and likewise carve out the vertically oriented link form (151) in-between two horizontally oriented link forms (152), thus termed interlaced; and thereby altogether avoid a “joint” in any link (160). Term “link form” (151, 152) is used for incompletely machined links.
Noteworthy that vertical and horizontal orientations are only relatable to intra-link forms since each link form or link is vertical and horizontal or inclined during machining as well as subsequent process and use. In different words, “vertically oriented” could be replaced with “firstly oriented” and “horizontally oriented” could be replaced with “secondly oriented”. Crudely, in the preferred embodiment with a horizontal machining center, the links are generally machined while in a vertical form and therefore such nomenclature should not be construed to limit the invention.
Figures 20-24, between each vertically oriented link form (151) and horizontally oriented link form (152), that is, the intra-link gap (146), the rod material is removed after discretely rotating the slender rod (140) to an inclined position wrt the cutting tool (120) such that at least a minimal joining bridge (181) is consciously retained between each end of the horizontally oriented link forms (152) and the vertically oriented link forms (151). In a preferred embodiment, such machining is done in two major orientations generally at 90 degrees to each other.
Grossly, the process (200) of machining comprises the steps of:
a. Advancing by the automated feeder set-up (105) at least a machining segment (147) of the slender rod (140),
b. Machining a vertically oriented link form (151) and two opposite partial lengths of horizontally oriented link forms (152),
c. Machining an inter-link gap (145) within the vertically oriented link form (151),
d. Rotating the slender rod (140) by a prescribed angle and machining an intra-link gap (146) in-between inner ends of vertically oriented link form (151) and partial lengths of horizontally oriented link forms (152) retaining a joining bridge (181) in-between,
e. Rotating the slender rod (140) by a 90 degrees and machining in-between inner ends of vertically oriented link form (151) and partial lengths of horizontally oriented link forms (152) retaining a joining bridge (181) in-between,
f. Rotating and advancing the slender rod (140) by a next machining segment (147),
g. Machining another partial length of the now vertically oriented link form (151) and two opposite partial lengths of horizontally oriented link forms (152),
h. Machining within the vertically oriented link form (151),
i. Rotating the slender rod (140) by a prescribed angle and machining the intra-link gap (146) in-between inner ends of vertically oriented link form (151) and partial lengths of horizontally oriented link forms (152) retaining a joining bridge (181) in-between,
j. Rotating the slender rod (140) by a 90 degrees and machining the intra-link gap (146) in-between inner-ends of vertically oriented link form (151) and partial lengths of horizontally oriented link forms (152) retaining a joining bridge (181) in-between, and
k. Repeating till an end of the slender rod (140).
This joining bridge (181) is crucial so that the just completed horizontally as well as vertically links forms continue to remain in a straight line in the Z-axis. In absence of consciously maintaining such joining bridges (181), the respective links (160) would start drooping as the rod material retained as the joining bridge (181) tends to disappear by continuing machining, and would aggravate in the influence of gravity and machining vibrations. Such an undesired situation would imply uncontrolled movement of link forms and would adversely impact machining process resulting into less than perfect machining!
The joining bridge (181) has extra-thin ends (182) on either side of varying appearance depending on corresponding shape of individual link (160), illustratively alternative forms of arrays of links (180a, 180b, 180c, 180d etc.), Figures 25, 26. The shape and numbers of the joining bridge(s) (181) is immaterial as it meets two objectives:
1. To hold all links against one another even after completing machining action on the machining console
2. To be able to break like a “biscuit” or a “cookie” to reduce a handling volume of the machined yet unfinished chain or array of links (180).
The rod material of the joining bridge (181) and the extra-thin ends (182) are eliminated by a combination of a plurality of compatible supplementary processes.
Figure 6, to pre-empt undesired biscuit-like breaking and thereby drooping of machined links the machined links with joining bridge (181) nearest to the under-machining links, that is, the link forms (151, 152), are provided with a dynamic anti-gravity support arrangement (135), supporting few links (160) in the link form (151, 152). This dynamic anti-gravity support arrangement (135), while avoiding gravitational fall has to be non-interfering with the forward, back and forth z-axis movement of the slender rod (140). The anti-gravity support arrangement (135) is a mechanical arrangement. In Figure 6, the anti-gravity support arrangement (135) is a tensioned rope (136) that maintains a pull force to counter gravity fall. Alternatively, this is a contact-less arrangement including an electro-magnetic arrangement. Illustratively, levitation can be deployed to achieve a suspension like arrangement.
To ensure that the minimum joining material is indeed technologically minimal, an analysis of
- Diameter, hardness and machinability of the raw material, and
- Compatible cutting tool (120) of optimum strength and minimum diameter
is done. A rotational speed and rate of depth feed of the cutting tool (120) is then worked out which would provide machined outcome with optimum surface finish.
Illustratively, a 3mm diameter titanium rod would be machined by a cutting tool (120) of narrower diameter and at a lesser cutting speed, while a 6mm diameter titanium rod would be machined relatively faster.
A machined array of links (180) obtained from the machining console (115) is joint-less. Machining of each link (160) is with high precision and surface quality. It is known that precision machining may lead to sharp edges between non-coplanar surface, besides the intentionally retained joining bridge (181) and the extra-thin ends (182), and therefore the plurality of compatible supplementary processes as below described is deployed to produce a useable product, produced more economically than finer machining!
Figure 5, following compatible supplementary processes are deployed in the preferred embodiment the present inventive process of producing joint-less array of links (180):
Contours smoothening (191):- By minimal use of diamond files, micro-grinding wheels, abrasive papers the machined array of links (180) is smoothened around rough edges and contours, and exposed surfaces, without significant material removal, besides clearing the joining bridges (181) and the extra-thin ends (182).
Ultrasonic Cleaning (193):- The machined array of links (180) are placed in a cleansing solution and subjected to ultrasonic vibrations, thereby agitating the cleansing solution fluid and caressingly clean all surfaces including hard-to-reach surfaces due to the entangled construction. Noteworthy that such ultrasonic vibratory cleaning would not be worthwhile in links produced individually, particularly since those links undergo messy joining and assembly process and cleaning with such delicacy is ineffective as well as wasteful.
Identification and traceability (195):- Towards effective marketing including traceability of such a premium possession of users, embossing by a stamping die is incorporated on identified links, without compromising on aesthetics.
Surface preparation (197):- Matte finish in itself is a valuable addition in appeal of premium products. Furthermore, a matte surface is a prudent preparation for further surface enhancements. The present process incorporates a controlled propulsion process of abrasive particles at controlled speeds and orientation, that removes any surface imperfections and improves the adhesion of any coatings or finishes/finishing process applied later.
Two-step Blackening (199):-
- A first blackening process comprises heating the machined array of links (180) in a furnace at 430°C - 530°C for 7 to 15 minutes, when the heat and temperature causes following controlled oxidation reactions:
• Titanium: Ti (s) + O₂ (g) → TiO₂ (s) (Titanium Dioxide)
• Zirconium: Zr (s) + O₂ (g) → ZrO₂ (s) (Zirconium Dioxide)
Oxide layers thus formed are black and ceramic-like, which darkens the surface of the links, enhancing their aesthetic appeal and corrosion resistance.
- Blackening at this stage provides a durable finish that lasts longer in various environments.
-Annealing at room temperature ensures the material bonds well with base surface of links and retains its strength and stability.
-A second blackening process is similar to the first, to form a second protective layer.
This double blackening enhances the depth and durability of the blackened finish. It also provides an additional layer of protection against wear and corrosion.
The process of double blackening is feasible consequent to presence of Zirconium in the rod material of titanium; and a blackening layer of up to 40 micros is providable.
Polishing and lustering (198):- Done using blue and white luster compounds, providing a mirror-like shine to the surface.
Noteworthy, that some of the above supplementary processes would fail to result into comparable enhancement in finish and appeal since links with joints of any nature and technology including soldering etc. cannot have a base surface as smooth as a joint-free surface producible by the present inventive process and therefore even after deployment of such processes, the end product fails to match joint-less chains producible by the present process.
Figure 26, it implies an array of assorted links is most economically producible through the present invention with a corresponding machining segment (147) calculation and a respective programming sub-routine for such array of links of assorted links. In such requirement the inter-link gap (145) and the intra-link gap (146) is a summation of corresponding shape and contour of the link on either side. Such a prudent programming application is a significant enhancement to machining capability of such systems with NIL investment in manufacturing infra-structure.
, Claims:We claim:
1. A system (100) and process (200) of producing a joint-free array of links (180), the system (100) comprising a computerized numerically controlled (CNC) machining console (115), an automated feeder set-up (105) and a precision control unit (125), characterized by:
the precision control unit (125) programmed to continuously feed a slender rod (140) to the CNC machining console (115), the automated feed set-up (105) configured to progressively move a slender rod (140) forward, as well as back and forth, along a Z-axis, rotate the slender rod (140) around the Z-axis, in a clockwise or an anti-clockwise direction,
the CNC machining console (115) having a plurality of horizontal cutting tools (120) with rectilinear movement at least in an X-axis, and rectilinear movement in a Y-axis, coupled with rotational freedom around the X-axis in a prescribed synchronism with the automated feed set-up (105),
a machining segment (147) of the slender rod (140) discretely machined into a link (160) and two partial lengths of links (160) on either side, the slender rod (140) continuously converted into a joint-less interlaced array of links (180) by cumulating machined machining segments (147), with a joining bridge (181) in-between an inner-ends of each horizontally oriented link forms (152) and adjacent vertically oriented link forms (151) on either side of each link (160) of the array of links (180).
2. The system (100) and process of producing the joint-free array of links (180) as claimed in claim 1, wherein the machining segment (147) comprises two partial lengths of the links (160) on either side of the link (160) having an inter-link gap (145) in-between, and at least two intra-link gap (146) within two adjacent interlaced links (160) on either side.
3. The system (100) and process (200) of producing the joint-free array of links (180) as claimed in claim 1, wherein the slender rod (140) is a roll of slender rod (140).
4. The system (100) and process (200) of producing the joint-free array of links (180) as claimed in claim 1, wherein the joining bridge (181) has extra-thin ends (182).
5. The system (100) and process (200) of producing the joint-free array of links (180) as claimed in claim 1, wherein the system (100) further comprises a dynamic anti-gravity support arrangement (135) nearest to link forms (151, 152) in the machining console (115), supporting the links (160).
6. The system (100) as claimed in claim 5, wherein the anti-gravity support arrangement is a mechanical arrangement.
7. The system (100) as claimed in claim 5, wherein the anti-gravity support arrangement is a tensioned rope (136).
8. The system (100) as claimed in claim 5, wherein the anti-gravity support arrangement is a contact-less arrangement including an electro-magnetic arrangement.
9. The system (100) and process (200) of producing the joint-free array of links (180) as claimed in claim 1, wherein the process (200) comprises the steps of:
a. Advancing by the automated feeder set-up (105) at least a machining segment (147) of the slender rod (140),
b. Machining a vertically oriented link form (151) and two opposite partial lengths of horizontally oriented link forms (152),
c. Machining an inter-link gap (145) within the vertically oriented link form (151),
d. Rotating the slender rod (140) by a prescribed angle and machining an intra-link gap (146) in-between inner ends of vertically oriented link form (151) and partial lengths of horizontally oriented link forms (152) retaining a joining bridge (181) in-between,
e. Rotating the slender rod (140) by a 90 degrees and machining in-between inner ends of vertically oriented link form (151) and partial lengths of horizontally oriented link forms (152) retaining a joining bridge (181) in-between,
f. Rotating and advancing the slender rod (140) by a next machining segment (147),
g. Machining another partial length of the now vertically oriented link form (151) and two opposite partial lengths of horizontally oriented link forms (152),
h. Machining within the vertically oriented link form (151),
i. Rotating the slender rod (140) by a prescribed angle and machining the intra-link gap (146) in-between inner ends of vertically oriented link form (151) and partial lengths of horizontally oriented link forms (152) retaining a joining bridge (181) in-between,
j. Rotating the slender rod (140) by a 90 degrees and machining the intra-link gap (146) in-between inner-ends of vertically oriented link form (151) and partial lengths of horizontally oriented link forms (152) retaining a joining bridge (181) in-between, and
k. Repeating till an end of the slender rod (140).
10. The process (200) of producing the joint-free array of links (180) as claimed in claim 9, wherein machining the slender rod (140) is stripping of rod material in several identified sectors (142), sequentially in a first division (141a), a second division (41b), a third division (141c) and a fourth division (141d) in order to minimize movement and changing of cutting tools (120).
11. The process (200) of producing the joint-free array of links (180) as claimed in claim 9, wherein the machining of the intra-link gap (146) is by progressively moving the slender rod (140) and or discretely rotating the slender rod (90) as per an assorted profile of the link (160, 160a, 160b, 160c, 160d).
12. The process (200) of producing the joint-free array of links (180) as claimed in claim 9, wherein the array of links (180, 180a, 180b, 180c, 180d) have an assorted profile of the link (160, 160a, 160b, 160c, 160d).
13. The process (200) of producing the joint-free array of links (180) as claimed in claim 9, wherein the process (200) has a compatible supplementary process of contours smoothening (191) including removal of joining bridge (181) and extra-thing ends (182) by diamond files, micro-grinding wheels, abrasive papers whereby the machined array of links (180) is smoothened around rough edges and contours, and exposed surfaces, without significant material removal.
14. The process (200) of producing the joint-free array of links (180) as claimed in claim 9, wherein the process (200) has a compatible supplementary process of ultrasonic cleaning (193) in a cleansing solution subjected to ultrasonic vibrations, thereby agitating the cleansing solution fluid and caressingly clean all surfaces including hard-to-reach surfaces due to the entangled construction.
15. The process (200) of producing the joint-free array of links (180) as claimed in claim 9, wherein the process (200) has a compatible supplementary process of identification and traceability (195) whereby a stamping die impression is incorporated on identified links, without compromising on aesthetics.
16. The process (200) of producing the joint-free array of links (180) as claimed in claim 9, wherein the process (200) has a compatible supplementary process of surface preparation (197) by a controlled propulsion process of abrasive particles at controlled speeds and orientation, that removes any surface imperfections and improves the adhesion of coatings or finishes/finishing process.
17. The process (200) of producing the joint-free array of links (180) as claimed in claim 9, wherein the process has a compatible supplementary process of two-step blackening (199), wherein:-
- a first blackening process comprises heating the machined array of links (180) in a furnace at 530°C, when the temperature causes a chemical reaction that darkens the surface of the links, enhancing their aesthetic appeal and corrosion resistance.
- annealing at room temperature ensures the material bonds well with base surface of links and retains its strength and stability, and
- a second blackening process as a repetition of the first blackening process, forming a second layer of protection against wear and corrosion.
18. The process (200) of producing the joint-free array of links (180) as claimed in claim 9, wherein the process (200) has a compatible supplementary process of polishing and lustering (198) using blue and white luster compounds, providing a mirror-like shine to the surface.