Abstract: A door bushing system includes bushings formed as part of a molded resin door jamb in an insulated steel shell safe door. The mold for the door jamb is designed to form as many bushings as are required and can also form stubs or sleeves for mounting other safe components. The bushings can support parts of such components as combination locks, key locks, and door handles. The combination lock and the handle have spindles whose opposite ends have identical configurations to facilitate assembly. The spindles are also made from resinous material to reduce heat transmission and to allow attachment by insert molding. Because the bushings are installed automatically with the door jamb, this door bushing system eliminates the need for separate installation of bushings after assembly of the door, ensuring proper alignment and reducing costs.

Abstract: A portable security case (10) includes a base (12) and a lid (14). A cable lock (32) locks both the lid (14) to the base (12) and the base (12) to another object (59). A spring catch (66) and dead bolts (82) also lock the lid (14) to the base (12). A spring latch (68) prevents the spring catch (66) from unlocking when the cable lock (32) is locked. A cable (40) is captured in different positions within the base (12) for adjusting its length, and hinges (91 and 93) are mounted in interior side walls (28 and 30) of the base (12) to provide an uninterrupted parting line between the base (12) and the lid (14).

Abstract: A fire-resistant safe is made with internal and external shells that are filled with insulation material. Hollow reinforcements interconnecting the two shells are formed as cone-shaped recesses in the internal shell having truncated bottom portions attached to the external shell. The insulation is made of a water-bearing material and the recesses are made of a resin material that melts at a temperature in excess of the boiling point of water. Funnels are formed in the external shell for adding the insulation material in a liquid state. An escutcheon for covering the funnels is anchored to the insulation material by stakes that are embedded in the insulation material before the material hardens into place.

Abstract: A fire-resistant safe is made with internal and external shells that are filled with insulation material. Hollow reinforcements interconnecting the two shells are formed as cone-shaped recesses in the internal shell having truncated bottom portions attached to the external shell. The insulation is made of a water-bearing material and the recesses are made of a resin material that melts at a temperature in excess of the boiling point of water. Funnels are formed in the external shell for adding the insulation material in a liquid state. An escutcheon for covering the funnels is anchored to the insulation material by stakes that are embedded in the insulation material before the material hardens into place.

Abstract: A fire-resistant safe has a main body and a closure, both of which are formed from integral resin shells filled with insulation materials. When exposed to fire, a portion of the resin material burns away leaving gaps between the insulation materials of the main body and closure. However, formation of convection air currents in vertical sections of the gaps is resisted by reducing spacings between insulation materials of the main body and closure. The amount of heat energy carried by the convection air currents is similarly reduced, thereby avoiding significant concentrations of heat that can promote burning through the gaps.

Abstract: A fire-resistant case for protecting electronic storage media includes a main body and lid, each of which is assembled from a pair of subassemblies. The outer subassemblies of the lid and main body are made from an integral resin body having inner, outer, and intermediate shells for encasing a layer of water-bearing material. The outer shells form the outer skin of the case, the inner shells form a moisture-resistant layer, and the intermediate shells form an outer seal between the main body and lid. An inner subassembly of the main body is built up from an inner repository of heat-conducting material, slabs of phase-changing material, and a foam insulation that encases the inner respository and phase-changing material. The foam insulation is formed as a self-skinning foam for forming a part of an inner seal between the main body and lid. An inner subassembly of the lid is constructed in a variety of ways consistent with the purposes of the other named layers of the case.

Abstract: A dobule-walled plastic box 20 is molded from a single parison 50 in an unlimited depth by closing the bottom of parison 50 and draping it downwardly over a core 60 so that a leading part of the parison forms an inside wall of the box and a following part of the parison forms an outside wall of the box. After parison 50 is draped over core 60, outer mold parts 61 close around the core and the draped parison; and the box is blown in a cavity between the core and the outer mold parts. The parison can be ballooned while draping down over the core to enlarge the parison to stand out from and surround the core, which can be raised during the draping process. Parison 50 can also be deballooned after draping to stay within the confines of outer mold parts 61 while core 60 raises and while the outer mold parts close.

Abstract: A combination lock assembly for safes in which the combination can be easily reset without dismantling the assembly or changing its original adjustment for smoothness and consistency of tumbler wheel motion. The tumbler wheel and spacing washer components of the assembly are all mounted on a bushing that also includes an end cap. The tumblers and spacers are spring biased by a wave washer so that the drive tumbler, which includes a plurality of angularly spaced holes, presses against the end cap. One of the holes is aligned with a drive stud on the drive cam that is used to position the tumblers. In the event the drive tumbler should receive uneven pressure from the drive studs (e.g., due to improper alignment of the safe's drive spindle), the tumbler wheels and washers are all held together by the bias of the wave washer and are maintained with their engagement surfaces parallel with each other, permitting proper operation without undesirable wear.

Abstract: A gusseted double-walled box is formed of a parison that is draped and blow molded according to the following process. A blow molding parison (10) being draped around a generally rectangular mold part (12) is spread from its extruded cylindrical shape into a generally rectangular shape (14), as it descends from an extrusion head (11). Before the open bottom (20) of the parison reaches a clamp (25) on the mold part, a jet of air is blown downward through the open bottom to draw in the parison's side and end regions (21 and 22 respectively). This reduces the size of parison (10) and helps it fit within the clamp and also forms the end regions (22) of the parison into a pair of opposed pleats (23) extending inward from the ends of the pinch-off line when clamp (25) closes. Further descending of the parison unfolds the pleats into gussets (24) extending toward corner regions (27) of mold part (12) so that the parison can drape around the mold part corners.

Abstract: A universal lock mount for use with a variety of different types of safe locks. It includes an integral resin structure having a bushing portion and a mounting plate portion. The bushing portion supports lock components, and the mount also includes a retaining cap which is fused to the outer end of the bushing portion to hold the components as an independent assembly. Resin spacing washers minimize wear and provide for smoothness and consistency in the movement of the lock assembly components. Use of the mount permits the lock components to be preassembled, tested and adjusted prior to installation so that the resulting assembly functions as an independent lock element. The universal mount also facilitates security of the safe. Because the assembly is independent of the spindle/driver mechanism used to position its components, removal or destruction of the spindle/driver mechanism does not affect the components supported on the universal mount, and the safe remains locked.

Abstract: A double-walled plastic box (20) is molded from a single parison (50) in an unlimited depth by closing the bottom of parison (50) and draping it downwardly over a core (60) so that a leading part of the parison forms an inside wall of the box and a following part of the parison forms an outside wall of the box. After parison (50) is draped over core (60), outer mold parts (61) close around the core and the draped parison; and the box is blown in a cavity between the core and the outer mold parts. The parison can be ballooned while draping down over the core to enlarge the parison to stand out from and surround the core, which can be raised during the draping process. Parison (50) can also be deballooned after draping to stay within the confines of outer mold parts (61) while core (60) raises and while the outer mold parts close.

Abstract: A blow molding parison (10) being draped around a generally rectangular mold part (12) is spread from its extruded cylindrical shape into a generally rectangular shape (14), as it descends from an extrusion head (11). Before the open bottom (20) of the parison reaches a clamp (25) on the mold part, a jet of air is blown downward through the open bottom to draw in the parison's side and end regions (21 and 22 respectively). This reduces the size of parison (10) and helps it fit within the clamp and also forms the end regions (22) of the parison into a pair of opposed pleats (23) extending inward from the ends of the pinch-off line when clamp (25) closes. Further descending of the parison unfolds the pleats into gussets (24) extending toward corner regions (27) of mold part (12) so that the parison can drape around the mold part corners.

Abstract: A double-walled plastic box (20) is molded from a single parison (50) in an unlimited depth by closing and holding a bottom region of the parison at the bottom of a cavity (30), bringing together parts of a core (40) above the cavity to close off an upper region of the parison, moving the core, the cavity, or both vertically to position the core within the cavity and invert the parison so that a lower region of the parison forms an outside wall of the box against an inside surface of the cavity and an upper region of the parison forms an inside wall of the box against an outer surface of the core. The parison is then blown into a double-walled box (20) in the shape of an enclosed space between the cavity and the core.

Abstract: A double-walled plastic box 20 is molded from a single parison 50 in an unlimited depth by closing the bottom of parison 50 and draping it downwardly over a core 60 so that a leading part of the parison forms an inside wall of the box and a following part of the parison forms an outside wall of the box. After parison 50 is draped over core 60, outer mold parts 61 close around the core and the draped parison; and the box is blown in a cavity between the core and the outer mold parts. The parison can be ballooned while draping down over the core to enlarge the parison to stand out from and surround the core, which can be raised during the draping process. Parison 50 can also be deballooned after draping to stay within the confines of outer mold parts 61 while core 60 raises and while the outer mold parts close.

Abstract: A generally rectangular, double-walled box 10 is blow molded in a pair of separately formed diagonal halves 10a and 10b, each including adjoining side walls 11 and 12 subtending a diagonal half of the bottom 15 of box 10. Walls 11 and 12 of each diagonal half are oriented obliquely to the parting plane 43 of a mold 40 that has a cavity 42 and core 41 for forming the inner and outer walls of each box half 10a and 10b. The halves are assembled together along a junction region 13 and 14, preferably so as to trap a hinged cover 20. By filling the interwall cavities of the box with a suitable insulation material, the box can be used for fire resistant storage or cold storage.

Abstract: A double-walled plastic box 20 is molded from a single parison 50 in an unlimited depth by closing and holding a bottom region of the parison at the bottom of a cavity 30, bringing together parts of a core 40 above the cavity to close off an upper region of the parison, moving the core, the cavity, or both vertically to position the core within the cavity and invert the parison so that a lower region of the parison forms an outside wall of the box against an inside surface of the cavity and an upper region of the parison forms an inside wall of the box against an outer surface of the core. The parison is then blown into a double-walled box 20 in the shape of an enclosed space between the cavity and the core.

Abstract: A bushing 10 for a safe door combination lock supports a spindle 20 extending through inner and outer door walls 13 and 12 separated by a space filled with insulation. A stub 15 secured in a hole 17 in the inner wall 13 by a rotational rivet 16 has an axial bore hole and a machined periphery for receiving components of the combination lock. A thin walled tube 11 extends through the bore hole in stub 15 and through the space between the inner and outer walls. An outer end of tube 11 is flared against an outer surface of outer wall 12 and an inner end of tube 11 is flared against an inner end of stub 15. Tube 11 then receives spindle 20 for the combination lock without providing a large heat conductor through the interior of the safe. Also, if tube 11 and spindle 20 are driven into the interior of the safe with a punch, stub 15 retains the tumbler wheels of the combination lock to keep the lock secure.