Abstract: A process for making a cutting instrument includes cutting a blank from a plate or strip of Type 60 Nitinol, having a thickness of between 0.005″-0.500″ using an abrasive waterjet, wire electron discharge machining or laser cutting, and grinding top and bottom surfaces of the blank by rotating a grinder having cubic boron nitride or diamond abrasive particles on a cutting surface of said grinder against the knife blank at a surface speed of about 5000 to 7000 surface feet per minute and grinding to a depth of about 0.001 to 0.005 inches per pass to remove material along the blade surface. The surface of the blade is polished to a surface finish smoother than 20 microinches RMS using Turkish emery abrasive grinding/polishing materials on a buffing wheel driven by a high power motor. The blade is then finish polished to a mirror-like luster of 2 microinches RMS or less using a fine diamond buffing compound and a buffing wheel running at about 3000 RPM.

Abstract: A gun system has a two piece cannon assembly that is separated between a removable chamber instead of a traditional breech, and a projectile forcing cone. The chamber has a plug at one end that can accommodate any type of ignition system, and the other end is open and is attached to the barrel with a connection fitting. High pressure gases created by combustion of the propellant are sealed with a high-pressure gas compression seal at the interface between the chamber and the barrel. The connection fitting provides an attachment for a rear cannon bearing slide, which rides on rails attached to the main support structure, and also reacts any torque induced into the barrel from the actuation of the chamber/barrel locking collar. A turntable upon which are mounted two chamber elevating/support mechanisms and two projectile loader/rammer mechanisms is positioned around one of the main support structure legs.

Abstract: A continuously variable power transmission has a fixed mounting plinth, by which the transmission is mounted to a fixed structure, and an output shaft, to which an output device can be connected. A pintle having a flat radial slab and an axial arbor supports a radial piston pump rotor an one end of the arbor and a radial piston motor rotor on the other end of the arbor. A driven pulley surrounds the transmission and constitutes its exterior shell within which working fluid is contained. The pulley is coupled to a ring gear of a planetary gear set having a planet carrier with planet gears engaged between the ring gear and a sun gear. The sun gear is coupled to and drives the pump rotor, and the carrier is coupled to the output shaft. Working fluid pressurized by the pump is conveyed to the motor rotor to generate torque in the motor which is carried back to the planet carrier.

Abstract: The invention includes processes and products made by the processes. The processes include making a two-part mold having semi-cylindrical openings for the paddle shaft so that the paddle blade may be molded and co-cured directly on the paddle shaft. The mold surfaces correspond to the ultimate outer mold line of the paddle, and also are designed to express liquid resin from the centerline of the paddle outward toward its edges as the mold closes or to fuse and consolidate thermoplastic resin such as polypropylene on glass fiber. The mold closing and heating schedule is designed to partially cure the resin so that it flows outward through the reinforcing fiber at a controlled rate, preventing resin starvation of the fiber reinforcement and ensuring complete expulsion of any air bubbles in the reinforcing fiber. The mold is opened and the paddle is removed from the mold for trimming by a high speed CNC router to produce a paddle that conforms exactly to the desired peripheral shape.

Abstract: A full levitation magnetic bearing system with passive magnetic bearings that affords increased radial stiffness and load capacity includes two passive permanent magnet magnetic bearings, one each located on each side of the center of mass of the rotor to be levitated. An active axial magnetic bearing provides control for stable levitation. The magnetic bearing system provides increased radial stiffness and load capacity by the reduction or elimination of the unstable tilting moments generated by the individual passive permanent magnet magnetic bearings. The bearings are constructed so that they are concave toward the center of the rotor, with a radius approximately equal to the distance between the magnetic bearing and the central point about which tilt rotation would tend to occur. The individual magnetic air gaps are preferably constructed to be perpendicular to the axis of rotation.

Abstract: A parallel hydromechanical continuously variable transmission has a housing (107) that holds a make-up pump (52), and has internal cavities for holding operating assemblies of the transmission, including an axial piston pump (50) and an axial piston motor (60). The pump (50) and motor (60) each has a rotating element (206) and a non-rotating element (258). Each non-rotating pump element is mounted for tilting movement on trunnions (258P) in its own respective pair of mounting journals in the housing (107). The tilting axes of the non-rotating elements (258) lie transverse to the axes of rotation of the rotating elements (206). The pump (50) and the motor (60) are disposed side-by-side in the housing (107) with the axes of rotation approximately parallel to each other. A stationary manifold (70), fixed to the housing (107), has one surface in contact with the rotating pump element (206P) and a second surface in contact with the rotating motor element (206M).

Abstract: An impact absorber for protecting a protected item against damage or injury upon impact includes a formed metallic structure having at least one Nitinol member having a grounded portion in contact with a first structure positioned to engage the protected item, and an impact receiving portion. In one embodiment, the formed metallic structure includes a plurality of Nitinol wires connected together at opposite polar regions in the form of a wire-frame sphere. The wires in the wire-frame sphere may be superelastic austenitic Nitinol in a strained condition. A release device holds the wire-frame sphere in a collapsed condition and may be actuated to release the strained superelastic Nitinol structure to a deployed position at which the deployed superelastic Nitinol structure is positioned to engage and absorb energy from the protected item impacting the impact absorber.

Abstract: A composite flywheel rotor includes a flywheel hub having tapered outer surface and an axis of rotation and a flywheel rim having an axis of rotation coinciding with the hub axis of rotation. The flywheel rim has multiple rings axially press-fit together to precompress the rings to form a composite flywheel rim. Each ring is made of approximately equal radial thickness and the entire non-dimensionalized radial thickness ratio of the assembled rim should be between approximately 0.38 to 0.48. The rim is optimally made up of four or five individual rings, each of which rings has tapered inner and outer diameters, preferably tapered at small angles to produce large radial forces when the rings are pressed onto each other and the hub by pressing axially, resulting in a high radial compressive preload in the assembled rim. A taper angle of 1-5° is suitable.

Abstract: A method and apparatus for holding a part on a fixture in a precisely known predetermined position includes pressing a surface of the part against a vacuum head and sealing an annular elastomeric sealing ring against the part surface. A valve button of a valve is engaged by the part surface to open the valve and establish communication between a vacuum source. The part is pulled by the vacuum against a hard stop in the vacuum head having a fixed precisely known relationship to said vacuum head reference surface. The hard-stop can be mounted in the base of the vacuum head for pivoting about at least one axis to self-align the hard-stop face with the part face.

Abstract: A mobile computer docking mechanism which transforms a laptop computer into a fully capable desktop computing and telephony system. The invention facilitates the use of the laptop liquid crystal display screen while the laptop computer is in the docked position. The network, keyboard and power ports are connected in the docked position, and the entire desktop configuration has a very low profile taking up very little desktop space. The upright position and design facilitates proper docking and an adjustable ergonomic viewing position, elevation as well as angularity. A combination of two laptops can provide the ability to view and operate simultaneously.

Abstract: A flywheel uninterruptible power source has a charging system that uses a high frequency pulse width modulated inverter inside the motor drive with a very low frequency, line commutated converter that regulates by switching the alternating current from the utility power at frequencies under 200 Hz and 60 Hz. The placement of the motor power regulation switching is moved from the motor drive preferably to the input AC line current that provides power to charge the flywheel system. The switching is preferably done using natural commutation so that the devices are turned off when the current passes through zero for very low loss and device stresses. Preferable devices for switching include thyristors or triacs. The turn on switching can be accomplished using phase angle firing or in one embodiment zero cross over switching is employed to reduce harmonic distortion and radio frequency interference to the primary source.

Abstract: A building frame resistant to earthquakes, gale-force wind loads, fire, insects and rot includes a peripheral frame wall constructed of rectangular steel tubing. Side wall frame modules bolted together along adjacent edges, and end wall modules bolted together along adjacent edges and to the ends of the connected side wall modules form the peripheral frame wall. Diagonal bracing is built into selected side and end wall modules as required for the desired degree of wind resistance. Trusses made of various size tube such as 2×3 inch rectangular steel tubing for supporting a roof, including a hip roof, on the peripheral wall, are assembled and welded in a welding shop and the prefabricated trusses and wall modules are trucked to the building site. Multiple stories may be erected and fastened together by anchor brackets arranged bottom-to-bottom above and below the second and higher floors. The building frame is secured to a foundation by attaching the anchor brackets to anchor bolts set in the foundation.

Abstract: A light weight horseshoe made of Type 55 Nitinol is bio-compatible and non-corrosive. It can be shaped at room temperature to fit the horse's hoof, and is extremely durable for long life and infrequent shoe changes, which helps avoid shoe nail damage to the hoof. It has low thermal conductivity to protect the horse's hoof from heat and a high specific damping capacity to protect the horse's hooves and legs from shock and vibration and also make it a quiet shoe. The horseshoe material has low initial yield strength, so it conforms to the microtopography of hard surfaces, which improves the grip of the horseshoe on such surfaces, but when strained its yield strength increases greatly so it becomes effectively unbreakable in use.

Abstract: A tubular part having a tubular main body and an integral tubular protrusion projecting laterally from the side of the main body and in fluid-tight communication therewith is superplastically formed by inserting the tube in a cavity of a die base and heating the die to a temperature at which the material of which the tube is made exhibits superplastic properties. The distal end of a pull-rod is extended through an opening in the die base and through a hole in the side wall aligned with the opening. A pull-die is selected having a cross section larger than the hole and about equal to the desired internal cross section of the tubular protrusion. The pull die is attached to the distal end of the rod and (before or after attachment) is heated to about the superplastic temperature of the tubing material.

Abstract: A Nitinol element is threaded by first heating it to a temperature of about 800° C., and then applying a threading tool, such as a tap or die, to form the threads. Nitinol has a unique property of increasing yield strength as cold work is applied, but this property ceases to exist above a temperature of about 800° C. The strength of the material at this temperature, however, is sufficient to resist the torque applied by a threading die being screwed onto a Nitinol blank even though it is low enough to permit the Nitinol to flow when the cutting threads of the threading die are forced into the material. At this temperature, the Nitinol is not actually cut by the cutting threads of the tap, die or other threading tool, but instead, the material flows around the cutting threads to form threads in the Nitinol.

Abstract: The invention includes processes and products made by the processes. The processes include making forms and parts by friable mold casting or die casting using molten Nitinol poured or injected into the mold or die. After the Nitinol has cooled to a solid state, it is removed from the mold by disintegrating the friable material of the mold and is heated to an elevated temperature under high pressure to consolidate the Nitinol and remove any internal voids. The parts and forms are then heat treated to reduce brittleness and improve toughness and impact strength. The part may be hot machined to reduce it to near net size, and may be ground to reduce the part to the exact specified part size. For example, cylindrical parts can be centerless ground; balls can be ground in a conventional ball grinder; flat stock can be surface ground. For parts requiring a smooth surface finish, polishing or lapping provides the specified surface finish on the part, down to 0.5 microinch RMS or finer.

Abstract: A method of prescoring foam board for making composite panels includes impressing a pattern of ridges projecting from a surface of a die into at least one face surface of the foam board. The pattern of ridges on the die forms a pattern of indentations having three series of parallel linear indentations, each series being angularly offset from each series other by 60°. The ridges on the embossing die are pressed into the foam sufficiently deep that the the pattern of indentations impressed in the board surface after whatever springback occurs remain deep enough to enable volatiles generated in an interior zone of a panel to escape when drawn out by a vacuum pump when the foam board is heated under pressure between two face sheets of resin-preimpregnated fabric to form a composite panel.

Abstract: A superplastically formed, diffusion bonded sandwich structure having integral metal hardpoints, made by joining two superplastic metal core sheets together into a core pack by welding or diffusion bonding along a pattern of lines which form junction lines between the core sheets when the pack is inflated by gas pressure at superplastic temperatures. Face sheets are laid under and over the core pack and metal inserts are interposed between the face sheets and the core. All of the sheets in the pack are sealed together around an outside peripheral edge to create a gas tight envelope. The pack is heated to superplastic temperatures in a cavity in a die, and the top and bottom face sheets are diffusion bonded to top and bottom surfaces of the metal insert by application of heat and pressure from top and bottom inner surfaces of the die cavity.

Abstract: An electrical resistive heating system having a Nitinol heater element in the form of wire, rod strip or tube, is flexible, ductile, tough aid chemically non-reactive. The element has connectors at each end for leads from a controller that controls the flow of current through the heater element from a source of electrical power. The Nitinol heater element is treated to have an electrically insulating surface that is also hard and chemically non-reactive, so the heater element can be put in intimate contact with the materials or substrate to be heated without shorting or electrical shock to people or equipment. The controller uses temperature data feedback from a separate temperature sensor such as a thermocouple, or uses the resistance of heater element itself as a temperature sensor, since the resistance of the Nitinol changes with temperature in a predictable way.

Abstract: A kayak is disclosed having a cockpit for holding a paddler and having a deck with at least one hatch. The exterior mold line of the kayak presents smooth sleek lines that are uninterrupted by a protruding hatch cover or by unsightly straps and buckles holding the hatch lid in place. The kayak has a cockpit for receiving a paddler and at least one cargo hold with a water tight bulkhead between the cargo hold and the cockpit. A hatch well in the deck has a floor recessed below the level of the deck. A hatch rim is bonded and sealed in a hatch opening in the hatch well floor, and a water tight hatch cover is fitted on the rim to seal the hatch against ingress of water into the cargo hold. A peripheral recess around the hatch well receives the peripheral edge of a hatch lid, dimensioned to fit into the peripheral recess and lie flush with the deck. Retention rods protruding into the recess fore and aft hold the hatch lid against movement out of the recess.