Abstract: In a multiple axis electrical discharge machine having a pair of indexable turrets each of which carries a plurality of electrode cartridges each with a supply of electrodes, the improvement of individually releasable electrodes in each cartridge which are configured to be transferred to a tool holder to be precisely positioned therein; the machine further includes a programmable electrode tool holder carousel and opposed tool carriers for moving preselected combinations of tool holders and electrodes between an electrode transfer station and a tool changer for transferring the selected electrode to a servo driven spindle head.

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: A nozzle apparatus for focusing a beam of collimated radiation from a laser source has a spring mounted nozzle which contains the focusing lens or mirror system for establishing the actual size of the focal spot of the beam on a workpiece. Engagement of the tip of the nozzle with the workpiece or other obstacles will cause the nozzle to tilt away from the obstacle and means are responsive to such tilting movement to stop machine operation in order to clear the obstacle from the programmed path of operation of the spring mounted nozzle. Furthermore, means are provided to cause the entire assembly to be deflected upwardly when encountering an obstacle that is located in a centered relationship below the nozzle tip. The spring mounted nozzle repositions itself when it is free of the obstacle.

Abstract: A laser processing system consists of three dedicated work stations for cutting to length a family of parts such as exhaust pipes. The processing center includes three laser stations each having a laser beam rotator that receives a laser beam and directs it into a cutting plane for processing the products at each of the stations. These stations are selectively operated by use of an improved laser beam delivery system including a beam sharing platform that is programmed to selectively deliver a laser beam output to each of the work stations for processing products. The beam sharing platform includes a plurality of separate angularly adjustable, presettable mirror units that can be precisely aligned with the pipe delivery system and matched to the processing requirements of a given work station.

Abstract: A press for holding mold segments that are joined to form a mold cavity into which liquid chemicals are injected and reacted to form solid objects includes tie bar extenders to provide field adjustment of the press geometry and further includes booking plate spacers to unload booking plate hinge pins during mold clamping.

Abstract: Apparatus for manufacturing thin walled hollow parts such as automobile crash pads from dry thermoplastic powder includes a louver type valve system in the open end of a powder charge box and means for joining the charge box end-to-end with an open-ended heated mold for rotation so that the charge box will be inverted above the mold at the end of an upward swing movement during which the valve is closed to prevent flow of powder to the mold. Once the charge box is fully inverted the valve is opened to evenly distribute the powder into the mold by gravity flow to prevent excessive build-up of wall thickness on the mold surfaces.

Abstract: Apparatus for reducing the waste neck area in a mold of vinyl cast articles such as automotive arm rests, head rests and parts of similar construction includes a powder box of gellable material having a supply spout with its exposed outer surface area covered by a liner of heat insulating material; a waste inlet neck on a heated, machined nickel mold is sealed by the liner when the powder box is joined to the mold. The powder box spout is at room temperature and shields the inlet neck to prevent gel build-up on the inlet neck to effect considerable cost by both a reduction in waste deposits of gel and a reduction in labor required to trim a waste area on the mold. To obtain the coating, the mold is coated with powdered vinyl (hereinafter gellable material) by casting from the powder box to the mold and the excess material is removed from the mold by dumping it from the mold into the powder box.

Abstract: A flexible grinding cell in-process gage system includes a pallet assembly and gage bench fixture assembly with means to preset the gage for subsequent use at a grinding station. The preset pallet and gage are operated at the grinding station to produce a signal to compensate for any pallet mis-alignment at the grinding station prior to an automatic machining sequence.

Abstract: A polyurethane RIM method has two mixheads. Reactants are brought to each mixhead and are supplied as separate streams to two spaced cavities in a mold having a pre-formed porous mat separating the two cavities. One stream contains an isocyanate, polyol, chain extender and crosslinker selected to have a very low viscosity and which reacts to produce a high modulus armature or load bearing member. The other stream contains a polyol and isocyanate with additives that have relatively high viscosity to produce a semi-rigid polyurethane foam. At each mixhead the proportions of ingredients are controlled to give a desired isocyanate index to control the flex modulus and other properties of the loading bearing member and foam molded components of the product. The low viscosity material penetrates the porous mat to reinforce it and the porosity of the mat prevents the high viscosity material from entering the armature cavity so as to reduce the load capacity of the finished product.

Abstract: A hydraulic actuator with reduced interior volume includes a locking mechanism engageable with the main ram of the actuator to hold it in a fully retracted position without backlash. The locking mechanism comprises three locking jaws that move synchronously in a radial direction between lock or unlock position. Each of the jaws engage a groove cut into a rod adjacent the piston head of the main ram; the jaws are cammed into a locking position by a conical sleeve actuated by hydraulic pressure under the control of the main control valve. Jaw deactivation is accomplished by an opposed pressure which disengages the conical sleeve and the jaws are then spring biased into a cammed open position as the main ram begins to extend. Springs located between the individual jaw segments assist the camming action for opening the jaws.

Abstract: A plastic object is manufactured by a process including vacuum metallizing with a corrosion prone metal, namely indium, a dielectric substrate to form "islands" of the indium top coated with a clear resinous layer which encapsulates and insulates the islands, one from another. The indium islands are less than one thousand angstroms thick and have an average diameter of less than three thousand angstroms. The island structure is etched following the growth of the metal as it is deposited between the nucleation stage and the stage of channelization of formation of an electrically conductive film. The etchant is selected to clear channels between island structures to improve adhesion of a dielectric resinous top coat to the dielectric substrate by order of magnitude to adhesion to the islands.A preferred application of this invention is the manufacture of exterior automobile trim components the base structure of which is a flexible elastomer such as a thermoplastic urethane.

Abstract: A high pressure mix-head for use in reaction injection molding systems includes a full cross section plunger and a piston valve assembly selectively positioned in response to recirculation and pour cycles to control flow through recirculation passages formed on the O.D. surface of a mix-head sleeve.

Abstract: Apparatus and a process for manufacturing multiple color thin-walled hollow sheels for parts such as automobile door panels, consoles and instrument panels from dry thermoplastic plastisol includes a supply box with a divider to form two or more compartments in the box. The box divider cooperates with selectively positioned split mold parts defining a separation in an open-ended heated mold for separating the mold into two or more sections. Complementary open ends of the charge box and mold are joined. Then the apparatus is 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 resultant shell of cured material; thereafter the powder box is removed and the split mold parts are joined to clamp cast shell segments for fusion at a joint line.

Abstract: An apparatus for cleaning the slots of newly assembled armatures of chips and burrs. The apparatus includes centrally or radially mounted cylinder means and a plurality of radially aligned blades, with suitable linkage means connected threrebetween for moving the blades laterally through the slots upon reciprocal movement of the respective cylinder rod(s) to thereby clean out the slots.

Abstract: Apparatus for reducing the waste area in a mold for an article molded from a heat-fusing material by a powdered vinyl process, has a mold box disposed adjacent the backside of a mold surface for controlling the temperature over respective first and second areas of the mold surface. The waste area elimination is accomplished by isolating and insulating the section of the mold defining the waste area. A kerf is cut into the mold around the waste area to isolate the area. The kerf is filled with castable silicone to insulate the waste area from the heated segments of the mold. To obtain the coating, the mold is filled with powdered vinyl and the excess material is removed from the mold by dumping the plastisol from the mold into a return tank.

Abstract: Apparatus and a process for manufacturing thin walled hollow parts such as automobile crash pads from dry thermoplastic powder includes a louver type valve system in the open end of a powder charge box and means for joining the charge box end-to-end with an open-ended heated mold for rotation so that the charge box will be inverted above the mold at the end of an upward swing movement during which the valve is closed to prevent flow of powder to the mold. Once the charge box is fully inverted the valve is opened to evenly distribute the powder into the mold by gravity flow to prevent excessive build-up of wall thickness on the mold surfaces.

Abstract: A high pressure sealing system is disposed between a housing and a reciprocating member. One version has a reciprocating plunger and in another version is a reciprocating piston associated with a free floating piston.

Abstract: An EDM head has a single servo-controlled electric motor and a high ratio gear system that drives a wire electrode during both an EDM machining operation and a wire erosion compensation operation. An associated control system can be programmed to selectively drive the electrode to compensate for wire erosion and to control blind hole breakout.

Abstract: Apparatus and a method are provided to form the interior of a fuel injector spray tip by use of a cold forming punch to form a V-shaped spray tip interior configured to reduce fuel dribble and thereafter finishing the interior by use of an EDM electrode to form precision valve seat and fuel sack surfaces.

Abstract: Apparatus for manufacturing multiple color thin-walled hollow shells for parts such as automobile door panels, consoles and instrument panels from dry thermoplastic plastisol includes a supply box with a divider to form two or more compartments in the box. The box divider cooperates with selectively positioned split mold parts defining a separation in an open-ended heated mold for separating the mold into two or more sections. Complementary open ends of the charge box and mold are joined. Then the apparatus is 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 resultant shell of cured material; thereafter the powder box is removed and the split mold parts are joined to clamp cast shell segments for fusion at a joint line.