Abstract: A dual cell rear corner pillar for the operator's compartment of a pick-up truck is formed with longitudinally oriented front and rear tubular members. The dual cell tubular construction increases section strength for the rear corner pillar while maintaining packaging constraints for the rear pillar design. The front tubular member is nested against the rear tubular member to provide support therefor longitudinally and vertically. The forward tubular member is welded to the door opening panel seal flange, while the rearward tubular member is welded to the window flange and the back panel flange. The forward and rearward tubular members are also welded to one another to form a strong pillar structure. The dual cell configuration resists buckling and shares loading. The rear tubular member wraps around the front tubular member and transitions into the roof rail area, shortening the unsupported moment arm of the rear tubular member.

Abstract: A process for forming a hydroformed automotive component with an integrally formed attachment bracket or weld flange begins with a tubular blank manufactured through a roll-forming process to convert sheet metal into a tubular body portion having excess parent sheet metal material extending past the tube weld joint to define an integrated flange. This integrated flange tubular blank is then placed into a forming die and subjected to a conventional hydroforming manufacturing process to form the automotive component into the desired shape and configuration. One side of the forming die is formed with a slot defining a gap in which the integrated flange material is received to create the weld flange or attachment bracket when the die is closed against the integrated flange material while the hydroforming process is undertaken. Alternatively, the integrated flange material could be welded onto the tubular blank during the formation of the tubular blank.

Abstract: An improved method of manufacturing an assembly comprising at least two components. Assembly components are attached together to form a combined assembly. The combined assembly is engaged by a single framing fixture that establishes the spatial relationships between each of the assembly components. After the spatial relationships are final, the assembly is fixed having securing points that are accessible when engaged by the single framing fixture. The method significantly reduces the load-weld-load sequences used in conventional body-in-white framing processes for motor vehicles.

Abstract: One embodiment of the present invention is a seal apparatus (16) for an improved front-end to body-side joint (10) of a vehicle. The seal apparatus (16) includes a ring portion (36), a gate portion (38), and an intermediate portion (40) extending between the ring portion (36) and the gate portion (38). The ring portion (36) is utilized for receiving an open-ended tubular front-end structure (12) of the improved front-end to body-side joint (10). Additionally, the ring portion (36) is utilized for sealing an interface between the front-end structure (12) and a body-side structure (14). Further, the gate portion (38) is sized for insertion into an interior cavity (42) of the front-end structure (12) and for blocking communication through the interior. Also, the ring portion (36) and/or the intermediate portion (40) have a self-locating construction for positioning the seal apparatus (16) in a predetermined location (50) on the front-end structure (12).

Abstract: A front end assembly for a vehicle includes a U-shaped tubular structure, a body portion having a pair of laterally-spaced, longitudinally extending cowl sides, and, a pair of laterally-spaced A-pillar structures. The U-shaped tubular structure is secured to each A-pillar and each cowl side at longitudinally-spaced apart locations. The laterally-spaced connection points provide improved rigidity and reduce distortion.

Abstract: An automotive vehicle body includes a generally tubular, hydroformed cowl with integral mounting flanges which are welded to an engine compartment structural member and a cowlside member. The cowl may be hydroformed from several different preforms having both symmetrical and asymmetrical geometric characteristics.

Abstract: One embodiment of the present invention is an improved front-end to body-side joint (10) for an automotive vehicle. This joint (10) includes an integral front end structure (12) having a fender attachment portion (16) and one or more hinge-reinforcement portions (14). The fender attachment portion (16) is coupled to a fender (24). Moreover, the hinge-reinforcement portions (14) are attached to a pillar member (28) of a vehicle body (46) for supporting a door (20). The integral front end structure (12) is a master-locating component for positioning the fender (24) and the door (20) in a predetermined configuration within the joint (10).

Abstract: One embodiment of the present invention is an improved front-end to body-side joint (10) for an automotive vehicle. This joint (10) includes an integral front end structure (12) having a fender attachment portion (16) and one or more hinge-reinforcement portions (14). The fender attachment portion (16) is coupled to a fender (24). Moreover, the hinge-reinforcement portions (14) are attached to a pillar member (28) of a vehicle body (46) for supporting a door (20). The integral front end structure (12) is a master-locating component for positioning the fender (24) and the door (20) in a predetermined configuration within the joint (10).

Abstract: A front end assembly for a vehicle includes a U-shaped tubular structure, a body portion having a pair of laterally-spaced, longitudinally extending cowl sides, and, a pair of laterally-spaced A-pillar structures. The U-shaped tubular structure is secured to each A-pillar and each cowl side at longitudinally-spaced apart locations. The laterally-spaced connection points provide improved rigidity and reduce distortion.

Abstract: A method of designing a manufacturing process line. A process is identified as a set of discrete steps. A subset of steps is assigned to one of a plurality of standardized work cells. The work cells include a standardized workpiece presenter and a standardized processing tool. Additional subsets of discrete steps are assigned to a standardized work cell until the design for the manufacturing process is completed.

Abstract: A method of designing a manufacturing process line. A process is identified as a set of discrete steps. A subset of steps is assigned to one of a plurality of standardized work cells. The work cells include a standardized workpiece presenter and a standardized processing tool. Additional subsets of discrete steps are assigned to a standardized work cell until the design for the manufacturing process is completed.

Abstract: The use of a fabric sheath (2), or other article, on a conduit (1), for example a pipe or flexible hose, to provide abrasion resistance or other forms of protection, for example impact protection or cut-through protection, thereto; and fabric sheaths suitable for such use.

Abstract: A fabric cover (9, FIG. 2a), which is shrinkable at least in part, for encapsulating at least part of an expandable object such as an automotive airbag (1), the fabric cover being provided with a predetermined region of weakness (13), preferably a catch thread holding the edges of a woven fabric together to form a tubular or flat cover, which region of weakness will rupture when the said object expands by greater than a predetermined amount, e.g. in an automobile accident. The region of weakness (13) and preferably fabric regions (11) immediately adjacent thereto may be of a contrasting color to facilitate alignment of the region of weakness in the direction of expansion of the expandable object.

Abstract: A continuous process for preparing polyester prepolymer comprising the steps of esterifying a diacid with a diol, reacting the esterified product with additional diol, and passing the product downward through a countercurrent column reactor while inert gas flows upward through the column reactor. The resulting prepolymer product has fewer acid end groups than the esterified material.

Abstract: A cable splice case or other article for environmental sealing comprises a composite material having multifilament fibres therein, which fibres are blocked in order to prevent passage of fluid through the material in a direction parallel to its major surfaces.

Abstract: An arrangement using C-shaped track having inwardly directed flanges and mounted upon a rotatable base is provided such that objects conveyed in the track can be separated, fixed in position, rotated or indexed, and recombined in the track.

Abstract: Phosphorus is recovered from phosphorus mud by introducing a skip of phosphorus mud into a furnace, closing the furnace and contacting the skip inside the furnace with a pool of molten lead. Phosphorus vapour is distilled from the mud and recovered.

Abstract: A current collecting pole associated with an alkali metal-sulphur cell comprises a first layer of an electronically conducting material which is resistant to the corrosive action of sulphur and alkali metal polysulphides (e.g. carbon or graphite) and which defines a continuous surface in contact with the sulphur and alkali metal polysulphides and a second layer of a higher electronically conducting material which is in electrical contact with the first layer over the surface of the latter remote from the sulphur and alkali metal polysulphides.

Abstract: Novel organic polyphosphate mixtures are made by a process comprising a mixture of a plurality of polyphosphate salts of one or more primary, secondary or tertiary amines; which mixture has been obtained by a process comprising (1) forming an aqueous polyphosphoric acid solution comprising from 80 to 88% by weight of phosphorus penitoxide; (2) reacting said polyphosphoric acid solution with a primary, secondary or tertiary amine at a pH of from 4 to 12 and at a temperature of from 15 to 70.degree. C.Such mixtures are useful as builders in liquid cleaning compositions comprising surface active agents or alkali metal hydroxides or silicates with which they are more compatible in aqueous solution then are previously used polyphosphate builder materials.

Abstract: There is provided a method for preparing phosphorus compounds wherein phosphorus vapor containing P.sub.2 molecules is condensed at a temperature below the solidification point of red phosphorus and the resulting solid is then reacted with a phosphorus-reactive material. When the phosphorus-reactive material is water at an elevated temperature, phosphine is produced.