Abstract: An improved method of forming an article includes providing continuous woven, flat, helical tape of filaments and a continuous flat, helical tape of foil. The two helical tapes are interleaved to form a helical assembly having turns of filaments alternating with turns of foil. Deformation forces are applied against the turns of the helical assembly in a direction parallel to the central axis of the helix to bond the turns of the tapes of foil and filament together while maintaining the filaments free of axially extending forces. During the bonding of the turns of the helical foil and filament tapes, the tapes may be bonded to a housing or other component of an article to be reinforced. Radial reinforcing can be provided by including in the helical assembly a layer having filaments with central axes which are radial relative to the central axes of the filaments of the helical tape.

Abstract: The panel punch includes a main punch configured to punch a trapezoidal opening in an electrical panel to receive an electrical chassis connector and a secondary punch integral with the main punch and extending from opposite ends thereof configured to punch a U-shaped slot in the panel extending from the ends of the trapezoidal opening to receive mounting screws for physically attaching the electrical connector to the panel.

Abstract: A windshield washer pump including comprising an impeller chamber having a reversible impeller rotatably mounted therein and an inlet for windshield washer fluid communicating therewith. Dual outlets communicate between the impeller chamber and opposite ends of an adjacent outlet chamber. A piston is slidably mounted in the outlet chamber intermediate axially aligned tubular discharge passages extending from the outlet chamber. Oppositely disposed projections are formed on the piston for being alternately urged into engagement with the tubular discharge passages, permitting the alternate pumping of fluid through the tubular discharge passages.

Abstract: A rotational molding process for slush casting mold with plastisol includes providing a conveyor having a plurality of spaced reversing arm assemblies, each arm assembly having opposite ends carrying molds thereon; providing first and second conveyor paths for the molds on the opposite ends of each arm assembly and locating one of the first and second conveyor paths inside the outer perimeter of the other of the first and second conveyor paths; preheating a mold on one of the arm assemblies on the first conveyor path and filling the preheated mold with an excessive charge of plastisol to form a gel layer thereon while on the first conveyor path and thereafter dumping plastisol from the preheated mold for return to a supply source of plastisol; and simultaneously curing a gel layer on another of the arm assemblies by directing the mold through the second conveyor path as the preheated mold on the other end of the arm assembly is being filled and dumped whereby the movement of an arm assembly produces simultane

Abstract: An elongated stem extends through a bore in a sleeve having a preformed head at one end. The sleeve extends through aligned holes in one or more workpieces to be fastened together. Pulling the stem through the sleeve causes an enlarged tail on the stem to be drawn into the end of the sleeve opposite the preformed head. The sleeve thus expands, forming a blind head. The workpieces are sandwiched between the preformed head and the blind head. To prevent the stem from sliding out of the sleeve, a locking collar is provided within the sleeve bore. The collar is slideable from a first position spaced from the preformed head to a second position within the preformed head. The collar is engaged by a shoulder on the stem and is moved from the first position to the second position as the stem is pulled through the sleeve. When in the second position, the collar is prevented from further movement, and is deformed as the stem continues to advance.

Abstract: Apparatus and a process for manufacturing plastic shells having decorative features thereon includes a method for casting thermoplastic material against a heated mold by use of a combination mask and container unit (hereinafter referred to as the combination unit) that is joined to a known heated mold to deposit a first semi-cured deposit on the mold from supplies of material in the combination mask and container; the mask is configured to have a plurality of wire reinforced foot portions with sealing edges configured to be aligned with the sharp edges of recesses in the mold surface defining the decorative feature; when the combination unit is inverted it casts material only on the recesses to form a semi-fused deposit of a first color. The combination unit is separated from the mold which is then processed to a higher fusion temperature and a base layer of contrasting thermoplastic material is cast thereon to be bonded to the recess material prior to cooling and stripping the mold.

Abstract: An improved method and joint structure are provided for assembling a self-clinching fastener to sheet material, particularly thin sheet metal, in which an aperture and a peripheral flange are formed in the sheet metal; thereafter the shank portion of the fastener is inserted into the flange followed by clinching the fastener to the flange to secure the assembly. The sheet metal aperture and peripheral flange can be fabricated in a single work station in which the fabricating tooling punches the sheet metal aperture and extrudes or shapes the peripheral flange between a pair of forming dies. Assembly of the fastener joint with the flanged metal is performed in a second work station in which the fastener shank is inserted into the flange and then the head portion of the fastener is driven into the flange material to begin the clinching step.

Abstract: An apparatus 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. The 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 clearance 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: 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 shaft lock assembly has a stator and a plurality of radially disposed, reciprocating lock vanes that are moved on the stator to lock and release a shaft. The vanes are held in their locked position by a rotatable cam ring. A rotatable cam scroll lifts the vanes from their locked position and positions the vanes in their released position. The vanes and shaft have coacting surfaces to produce a regenerative separating force on the vanes from a locked shaft which is under torque as the shaft is unlocked.

Abstract: Apparatus for manufacturing a multitude of thin walled hollow plastic shells for parts such as automobile door panels, controls and instrument panels from dry thermoplastic powders includes a mold heating chamber with a tube sheet heating assembly operative to provide a hot air flow pattern with a profile which matches the outer profile of one of a plurality of molds that are selectively placed in the mold heating chamber thereby to uniformly heat a casting surface of the mold by an energy efficient process.

Abstract: A fastener stem collection device for attaching to a power operated fastening device for collecting fastener stems, having a reciprocating tube urged forward by air pressure against the fastening device, which tube has an air jet for introduction of pressurized air to its central bore to draw the fastener stem from the fastening device through the central bore and deliver it to a collection housing. The collection housing has a non-opaque inner tube with an open rear end, and an outer canister with a closed rear end and an open window located medially thereon. The outer canister is selectively affixable in a concentric relation with the inner tube to collect the stems during operation of the fastening device, but may be released and slid rearward of the inner tube to allow the collected stems to be discharged through the inner tube open end and out the outer canister window.

Abstract: A composite article is made by braiding a 3D article shaped preform including non-fugative braider reinforcing fibers and fugative fibers and removing the fugative fibers to form a plurality of matrix-ingress passages in the braided preform. During impregnation of the braided preform with a matrix material, matrix material is supplied to the interior of the preform via the passages. The fugative fibers typically comprise fugative monofilaments which are substantially larger in size than the non-fugative fibers to permit one or more dimensions of the preform and thus the composite article to be increased beyond the capacity of the particular braiding apparatus employed.

Abstract: A helicopter tail rotor (10, 130) includes a drive mast (12) having an axis of rotation (14). A first blade pair (20) is mounted for rotation about the drive mast (12). The first blade pair (20) includes a pitch change axis (54) perpendicularly disposed to the drive mast axis of rotation (14). A second blade pair (34) is mounted for rotation about the drive mast (12) and is spaced apart from and parallel disposed to the first blade pair (20). The second blade pair (34) includes a pitch change axis (60) parallel to the pitch change axis (54) of the first blade pair (20).

Abstract: Apparatus for manufacturing plastic shells having decorative features thereon includes a combination mask and container unit that is joined to a known heated mold to deposit a first semi-cured deposit on the mold from supplies of material in the combination mask and container; the mask is configured to have a plurality of wire reinforced foot portions with seal edges configured to be aligned with the sharp edges of recesses in the mold surface defining the decorative feature; when the combination unit is inverted it casts material only on the recesses to form a semi-fused deposit.

Abstract: An austempered ductile iron alloy with a mixed austenitic-bainitic structure is made by a method which enables the iron to withstand high cyclical stresses while having a high resistance to abrasion. Articles such as automobile roller-follower camshafts that are made from the iron alloy may have portions thereof selectively austempered to reduce the overall cost and time required to manufacture the article.

Abstract: A method for manufacturing decorative features in situ in a base layer cast plastic material includes the steps of providing a mold tool having a surface thereon which is recessed in the form of a desired decorative feature and includes a sharp break line between the recess and the surrounding mold surface; depositing a covering of thermoplastic material in the recess surface and heating the tool to melt the thermoplastic material on the recess surface to form segments of plastic corresponding to the desired decorative feature; thereafter cooling the covering and stripping it from the mold by separating it at the sharp break line interface between the deposited material on the recessed surface and a thin film membrane formed on the remainder of the mold surface so as to retain segments of material deposited in the recesses of the mold tool; reheating the mold tool recess to partially remelt the retained segments and thereafter depositing a base layer of thermoplastic material across the surface of the mold an