Abstract: A vehicle interior part such as a glove box door or console door and its method of manufacture includes an outer shell backed by foam material which is bonded to a mold insert that reinforces the part and defines an exposed back. The insert includes a peripheral edge spaced with respect to a continuously formed raw peripheral edge of the shell and further includes a flange portion that is post formed so as to be bonded to and located in a net out relationship with the raw edge to define a finished surface appearance.

Abstract: A pour mold includes two parts one of which forms a mold cavity and the other of which forms the lid for the mold cavity; the lid includes a retractable pilot pin and vacuum cups for positioning a mold insert within the mold cavity automatically upon lid closure. The pilot pin loosely pilots the insert in the mold as it closes and as the vacuum cups pull the insert toward the lid during such closure. The vacuum cups hold the insert against the lid continuously during foam injection, foam reaction and cure and as the lid is separated from the mold cavity part so as to automatically remove the finished part from the mold when the lid is separated therefrom.

Abstract: A retainer mold for forming foamed automotive articles, particularly instrument panels, after a thin vinyl skin shell has been mounted in the mold. The mold includes a plurality of die block assemblies mounted in recesses formed in a surface of the mold cavity. Each die block assembly includes a plate member secured in the recess, and a die block slidably mounted within controlled limits on the plate member, and adapted to be covered by the shell and to be moved as required to prevent wrinkling or bridging of the portion of the shell extending between adjacent die blocks.

Abstract: A prophylactic device is described which is adapted to be worn by a person to prevent the transmission of disease and sperm during sexual intercourse. The device may be adapted for use by a female person or by a male person. The device includes an elongated hollow pouch which has an open end and a closed end. The pouch has a thin wall member which is flexible and elastic. A continuous flange member is attached to the open end of the pouch and extends outwardly around the opening in the pouch. Attachment means secured to the flange attaches the device to the person wearing it. The device may be in the form of a garment worn by the person.

Abstract: A pneumatically operated stop for advanced workpiece comprises a pneumatic cylinder with a displaceable piston rod on which a stop is secured. A limit stop coacting with the extended piston rod defines the setpoint position of the stop. A precision limit switch for sensing the setpoint position of the stop generates a command signal when the stop moves away from its setpoint position. This signal controls a valve which is connected with the pneumatic cylinder. This valve connects the pneumatic cylinder in an unpressurized manner with the ambient atmosphere when the stop is occupying the setpoint position and no workpiece is resting against the stop. Once the stop has been displaced from its setpoint position by an advanced workpiece, pressure is applied to the cylinder by this valve in order to return the stop together with the workpiece to the setpoint position, and this pressure is maintained for a preselected amount of time by the valve.

Abstract: A snap-in clip for holding a retainer ring and wheel cover assembly in place on a wheel rim, wherein the clip includes a center strip for abutting against a portion of the retainer ring, three clip extensions formed on one edge of the center strip for extending through openings in a radially outer portion of the retainer ring, and a pair of U-shaped loops formed on the other edge of the center strip for snapping into place around an upturned inner peripheral edge portion of the retainer ring. A pair of retention fingers are also formed on the other edge of the center strip for being resiliently urged into an annular groove in the wheel rim to securely retain the wheel cover concentric thereon. A pair of shock tabs are also formed on the one edge of the center strip with swaged projections formed on the side edges thereof for engaging respective notches in the wheel rim to prevent rotation of the wheel cover assembly relative to the wheel rim.

Abstract: A process for drilling chamfered holes includes the steps of directing noncontact energy onto the outer surface of the part to form a recessed crater-like entrance with chamfered walls and thereafter directing a small diameter wire electrode adjacent the substrate and spark eroding the base without removing material from the chamfered walls so as to produce a combined passage through the part with a chamfered entrance leading to a smaller outlet. In one embodiment the part has a ceramic coating which is initially removed from the part by either focusing a laser beam to a penetration depth which removes the ceramic coating while forming the entrance and in another embodiment the coating is initially removed by imposing a high voltage pulse thereagainst from a spark erosion electrode of electrical discharge machining equipment.

Abstract: An electrical discharge machine including a pick-and-place system for transferring electrode refeed cartridges from a storage turret to an EDM work station from either one or two indexable turrets. A plurality of equally spaced electrode cartridge assemblies are each removably mounted on each turret by magnets and guide pins. A slide assembly is vertically positioned between a cartridge assembly load and unload elevation and an EDM work station elevation. The slide assembly includes a movable connector plug assembly selectively driven by an EDM cylinder fixed on the slide assembly. The connector plug assembly supplies refeed cylinders on a slide mounted cartridge assembly and vertically reciprocates a power connector receptacle and drive head on such cartridge assembly. The receptacle and drive head include an electrode guide board guiding one or more electrodes with respect to a workpiece.

Abstract: A composite plastic product is formed by a process which includes formation of a preform of high strength plastic having openings formed therethrough which are covered by a film barrier that is formed during molding of the preform; and wherein the preform is configured to be placed as a unit in a foam station at which material is foamed onto the insert without escape to its backside.

Abstract: An electrical force motor and servovalve combination has a rotary spool directly coupled to the motor shaft without requiring a rotary-to-linear motion convertor; the rotary spool is configured to have a cruciform metering section that cooperates with a flow sleeve having ports and slots configured to produce four-way flow patterns in a reduced length and volume valve package.

Abstract: A wire guide directs a wire electrode from a refeed mechanism in an electrical discharge machine EDM to a workpiece. The wire guide has a tension cap and a fixed wire guide body ceramic insert defining a precision guide slot for the electrode and wherein the tension cap is biased by a flex ring mounted on separated ends of the tension cap and body to retain them together. The biased tension cap has tapered surfaces at its exit end which produce a compound tension force on the electrode for maintaining a low friction force thereon during the life of the wire guide.

Abstract: A water jet trim head simulator has the same configuration and dimensions as a cutting or trim head nozzle on a water jet apparatus for trimming workpiece scrap. The simulator is used to guide a robot arm of the apparatus into various multi-axes trim head positions during a teaching mode of operation of the controller for the apparatus. The simulator includes mounting means for connection to the robot arm. The simulator further includes tracking means including a hollow body connected to a fiber optics bundle for directing light from a source to an objective lens for focusing a spot of light on a premarked trim path point on a master workpiece to establish one of a plurality of spatial points to be taught into the controller. The simulator further includes a feeler gauge for physically positioning the simulator with respect to the workpiece to assist the alignment of the light beam to its focused point on the workpiece.

Abstract: Apparatus and a process for trimming the tip of a spark erosion electrode includes a mirror system for selectively diverting a hole drilling laser beam through a path which intersects the tip of an electrode used to finish laser holes by spark erosion of the walls of the laser formed hole. The apparatus includes one mirror unit which is selectively positioned to intercept the hole drilling laser beam for diverting it for electrode trimming.

Abstract: An improved mold assembly which has a cavity mold part and a cover which form a space into which foam precursors are poured and the cover carries a mold insert which is bonded to the foam formed in the mold space; the cover carries a pour spout and a seal for preventing foam leakage from the space wherein the improvement comprises: means including a pour hole and a rotatable tube extending through said pour hole for defining a pour spout having an inboard end located within the space when the mold assembly is closed; seal means in surrounding sealing relationship with said inboard end of said rotatable tube; and means operative when the cover is closed and when the tube is located in the pour space for holding the insert within a desired variation of a designed location in said space and for holding the insert against said seal means to prevent foam leakage through the pour hole.

Abstract: Three-dimensional multi-colored plastic parts and a method for manufacturing such parts for automobile interior trim door panels, consoles and instrument panels and the like includes dry cast thermoplastic powder sized in the range of 60-400 microns and with two or more colors of particles mixed for distribution onto a heated mold section with the mixed powder particles being heated to randomly flow at particle margins to form two or more shade tones in a resultant three-dimensional multi-colored textured part of fuzed material.

Abstract: A wire guide directs a wire electrode from a refeed mechanism in an electrical discharge machine EDM to a workpiece. The wire guide has ceramic inserts defining a precision guide slot for the electrode and wherein one of the inserts is carried by a deflectable member spring biased to damp the electrode so as to maintain concentricity of holes formed by the electrode and thereby closely control the hole diameter.

Abstract: Apparatus and a process for manufacturing multiple color thin walled hollow shells for parts such as automobile door panels, controls and instrument panels from dry thermoplastic powders includes a powder box divider to form two or more compartments in a powder charge box and means for joining the chrage box divider end-to-end with a mold separation edge on an open-ended heated mold for separating the mold into two or more sections; each compartment of the charge box has a different color powder. The charge box and mold are joined and then are rotated so that the powder is distributed into each mold section by gravity flow with the powder from each section flowing to the divider which separates the colors so as to form two or more tones on a resulting shell of cured material.

Abstract: Apparatus and a process for manufacturing thin walled hollow plastic shells for parts such as automobile door panels, controls and instrument panels from dry thermoplastic powders includes a plurality of powder boxes and an open-ended heated mold. Each charge box is carried by an indexable carousel which has a drive motor controlled by a programmable controller to position the carousel to off-load a given color to a powder casting mold carrier which is associated with means for sequentially and continuously (1) preheating a mold; (2) dumping powder from an off-loaded color box into a heated mold; (3) curing the cast powder in the mold; (4) cooling the mold; and (5) stripping the part from the mold.

Abstract: An apparatus for making composite plastic product includes a mold insert with locating boss formations preformed from high strength plastic having openings formed therethrough; and wherein the insert is configured to be located on a mold cover which carries a locking device to hold the insert in place and wherein the locking device includes automatically operated knock-out means that engage the boss to separate a molded part from the lid when the locking device is released.

Abstract: A mold assembly for manufacturing composite plastic products includes a mold cavity part and a lid, which is joined to form a cavity for foam precursors. The precursors expand in the cavity in a known manner to fill the cavity with a suitable layer of foamed material, such as foamed urethane. The mold cavity supports an exterior shell and the lid supports an insert for reinforcing a finished composite product. A sleeve is integrally formed on the preformed shell and it in turn is located within an access port formed through wall of the cavity part to define a slideway for receipt of a pour head extension. The extension is selectively clamped and unclamped with respect to the shell sleeve by an inflatable seal clamp which is formed as an annular ring with a pressurizable passage connected to a source of selectively applied pressure.