Abstract: A linear to rotary ball screw actuator which includes both helical grooves and straight grooves longitudinally spaced apart on the outer surface of the shaft. Matching helical grooves and straight grooves are formed on opposed inner surfaces of first and second portions of relatively moveable housing to provide passageways filled with balls. A return passageway is provided through the housing by way of a straight bore parallel to the longitudinal axis of the shaft.Also disclosed is a ball screw rotary actuator of the type above described but having an additional section including either straight or helical grooves thereby to define an actuator having either a central helically grooved portion sandwiched between straight grooved portions or alternatively a central straight grooved portion with helical grooved portions on either side thereof.

Abstract: An instrument panel assembly, for mounting between the front support pillars of a vehicle, includes a panel body with openings for supporting and displaying instruments and gages and extending transversely between two front support pillars of a vehicle, with the panel body having first and second ends, and the panel body further includes adjustable, compressible bellows disposed at the terminal ends of the panel body for adjustment between extended and compressed positions to provide flush engagement with the front support pillars of the vehicle.

Abstract: An adjustment gear mechanism utilizing a plastic adjustment gear and integrally formed structures which securely retain a drive member. The plastic gear is formed to provide both a gear tooth arrangement which cooperatively meshes with a drive gear and an integrally formed adjustment member bore which provides prevailing torque for an adjustment member. The gear tooth arrangement on the plastic gear is formed to cooperatively mesh with a metal drive gear and withstand the tooth load and deflection applied by the metal drive gear. The drive member is non-adhesively retained by the integrally formed structures which maintain operative engagement between the drive member and the drive gear which it rotates. The structure and materials of the mechanism also provide adjustment-retaining purchase such that when a desired adjustment is achieved using the adjustment mechanism the adjustment resists disturbance by accidental, vibrational or other forces exerted upon either the drive member or the adjustment member.

Abstract: An improved joint structure and tooling apparatus are provided for assembling a self-clinching fastener to sheet material, particularly sheet metal. The fastener includes head and shank portions with an intermediate locking groove formed in the shank. The fastener shank projects through the aperture and the head is at least partially embedded within the peripheral material surrounding the sheet metal aperture. A portion of the peripheral sheet metal is disposed within the groove to form a mechanical interlock for securement of the joint assembly. The shank has an outwardly flared end portion which is staked so that it has an exposed surface coplanar or flush with the exposed, opposite surface of the sheet material relative to the embedded fastener head, which provides a smooth continuous undersurface of the joint.

Abstract: A process for forming a multi-colored integral vinyl skin shell including a heated mold and dual powder box arrangement wherein the mold is formed to include alternately positioned tear surfaces and recessed surfaces. After the first powder box supplies a layer of powder to cover all the surfaces to form a shell, the strips of shell on the tear surfaces are removed, after which the first powder box is replaced by a second powder box. The second powder box has a plurality of spaced dams or dividers formed therein such that the dams cooperate with the respective recessed surfaces of the mold to provide clearances therewith that permit different colored powders in the compartments between the dams to cover the previously cleared tear surfaces and to flow past the selectively formed free ends of the dams to become integrally secured to the adjacent edge portions of the shell segments remaining in the areas of the recessed surfaces of the mold, forming the multi-colored, integral plastic shell.

Abstract: An elongate igniter is disposed in the inner air chamber of an air blast nozzle coaxial with the longitudinal axis thereof such that the discharge tip of the igniter discharges a spark generally longitudinally downstream of the tip out of the path of swirling inner air flow and in the path of a reverse flow field of atomized fuel established downstream of the tip by relatively controlled inner and outer air swirl strengths.

Abstract: A modular fuel nozzle assembly includes a precalibrated, stand-alone valve module having a fuel metering valve and a precalibrated, stand-alone nozzle module having a fuel injection nozzle. The valve module and nozzle module include separate support housings joined together at an interface between the two modules to facilitate manufacturing, testing and maintainability of the fuel nozzle assembly. Fuel tubes extend across the interface to interconnect fuel passages in the joined modules.

Abstract: An airblast fuel injector tip is provided for reducing fuel vaporization problems as a result of high fuel temperatures without adversely affecting the airblast operational characteristics of the injector tip. The injector tip includes a fuel receiving chamber and a fuel discharge orifice downstream thereof and an arcuate, distensible, tubular valve member having a discharge end movable relative to a valve seat in the fuel receiving chamber in dependence on the pressure of fuel in the valve member to meter fuel to the fuel receiving chamber for discharge through the discharge orifice into a combustor.

Abstract: This disclosure illustrates and describes a test mold for the quantitative measure of the effects of formulation and/or process variable changes on some kinds of surface problems of a molded part caused by different degrees of imperfection or voiding underneath the part surface. The molded part can be single component or composite, solid or foamed. One example of the surface problem is the so-called "measles or cellulite" problem observed on the vinyl surface of a vinyl/foam composite due to the voids or rattiness within the foam. To accomplish this result, the mold has various sized, spaced apart, aligned openings formed in each of the front and rear walls of the mold, but with the centers thereof at different elevations in the respective front and rear walls. Removable rods inserted through the aligned mold wall openings produce longitudinal openings through the part which is molded around the rods, permitting the effect thereof on the surface of the molded part to be evaluated.

Abstract: A blind fastener comprises a tubular sleeve, a mandrel stem and an integral shear ring and locking collar assembly. The integral shear ring and locking collar assembly has a wedge-shaped bulbing portion for expanding the blind side of the fastener sleeve in response to a pulling force on the stem, and a leading finger which functions as a locking collar. As the mandrel is pulled axially away from the sleeve, the leading finger portion radially expands the body of the fastener sleeve while the wedge-shaped portion axially compresses the tail end of the sleeve to form a blind head. After forming the blind head, the wedge-shaped bulbing portion shears. The leading finger continues travelling through the fastener sleeve, radially expanding the sleeve to fill the hole between the sleeve and the workpiece. When the leading finger meets with an anvil washer it buckles into a recess formed in the sleeve so as to interlock the sleeve and the mandrel stem.

Abstract: A method of joining titanium to a dissimilar metal wherein a predetermined amount of heat and pressure is applied sufficient to plastically deform only one of the metals being joined. The heat and pressure combine to flow one metal into shaped surfaces existing in the second metal, maintain the joint in compression through differrential thermal expansion and bonding the deformed metal to the other metal. The method uses a temperature sufficiently low to effect bonding without any chance for the formation of excessive brittle intermetallic phases.

Abstract: An improved fastening nut is disclosed which is secured to an unthreaded stud which is inserted through a central bore in the nut. The bore includes a guide and retaining splines which provides alignment guidance during sliding insertion of the stud into the bore. The guide splines preferably has an annular configuration with an inner diameter slightly larger than the diameter of the stud so that the initial insertion of the stud does not produce significant frictional resistance. The bore of the nut further includes a plurality of helical threads, preferably twin leads having equal pitch, which are disposed in the bore axially distinct from the guide and retaining splines and terminate within the bore adjacent the guide and retaining splines. The internal helical threads have a crest diameter smaller than the stud diameter and also projects radially inwardly into the bore further than the guide and retaining splines.

Abstract: A fastener system for connecting first and second parts together includes a female fastener having a retention slot therein with an entrance portion, a stop portion and a fastener gripping segment located intermediate said entrance portion and said stop portion; a male fastener has an integral extension thereon insertable into said entrance portion and movable laterally of the slot to an interlocked position at the stop portion. The male fastener includes first surface means thereon engageable with the gripping segment for holding the male fastener in a stop position, and said male fastener further includes second surface means thereon to interlockingly connect the female fastener to the male fastener. The component parts of the fastener system are configured to be formed by use of die members separable in a straight draw.

Abstract: A carburetor and chain oiling assembly and method of manufacturing the same for use in a chain saw. The assembly generally comprises a carburetor section, an oil pump section and a cover connecting the two sections. The cover can connect the oil pump section to the carburetor section forming a cover for a carburetor fuel diaphragm and a working chamber with an oil pump diaphragm. The cover has a gas conduit between the carburetor housing and the working chamber such that gas pulses from an engine crankcase can be supplied to the working chamber to operably move the oil pump diaphragm to provide a continuous and automatic metered flow of oil to a saw chain.

Abstract: An exhaust configuration for a gasoline engine where the exhaust gas is merged with an air stream in a direction counter to the direction of flow of the air stream for reducing noise and for supercharging the engine and for reducing the amount of oil that may become entrained in the exhaust stream.

Abstract: Apparatus for manufacturing thin-walled hollow shells for parts such as automobile door panels, control and instrument panels and the like includes a charge box or powder box for supplying dry thermoplastic material to separate casting surfaces on a heated mold selectively connected to the charge box during a casting process. A selectively pressurizable inflatable seal gasket is connected to the charge box for sealing a division surface on the heated mold which surface separates the casting surfaces of the mold. The inflatable seal gasket includes a base portion fixed to the charge box; an inflatable core with expandable walls to bridge the distance between the charge box and the division surface and a seal bead that sealingly engages the division surface when the seal gasket is inflated to keep the division surface clean for a subsequent application of material to form a connector bond between previously cast two tone colored segments.

Abstract: A mower-mounted grass catcher and reel lawn mower assembly and method of making same. The catcher has two spaced-apart bores which receive two pins on the mower for mounting the catcher in a cantilever manner and on the mower. The bores are strengthened and are located in the opposite sides of the catcher which also has two handles for maneuvering the catcher. The upper panel and the lower panel of the catcher, adjacent the opening for the clippings, are reinforced with ribbing. The catcher is molded for extra-strength in the area defining the bores.