Abstract: A method for making an electric motor stator. An annular disk is cut so as to create a radially-outer ring portion having slots and a radially-inner ring portion having spokes engaged with the slots. This step is repeated on additional disks. Then, the radially-outer ring portions are stacked together to form the stator outer shell, and the radially-inner ring portions are stacked together to form a multi-pole assembly with the aligned spokes forming the poles. Coils are wound around plastic sleeves which are each brought to, and placed over, a corresponding pole member. Then, the multi-pole assembly is positioned within the stator outer shell with the pole members engaging the aligned slots. Finally, the joined-together radially-inner ends of the spokes are cut to create narrow slits.

Abstract: A subassembly for an ice maker includes a plastic ice cube tray having a housing located within and attached to the refrigerator freezer. The housing has spaced-apart ice cube cavities. An electrically heatable metallic film coating is attached to and generally covers the cavity surfaces. When the cavity surfaces have been heated to detach the formed ice cubes therefrom, in one embodiment, a mechanism is provided to rotate the tray upside down to release the ice cubes. In another embodiment, a fixedly-"upside-down" and semicircular-cylindrical-shaped ice cube tray is placed in a trough, which also has an electrically heatable metallic coating, and a mechanism is provided to rotate the trough to uncover the openings of the ice cube cavities in the tray to release the formed ice cubes when the cavity and trough surfaces have been electrically heated to detach the ice cubes therefrom.

Abstract: A hot water tank typically at 180.degree. F. and 55 psi operating temperature and pressure, respectively, comprises heat welded segments of compression formed ADZEL material, a polypropylene resin reinforced with a randomly oriented continuous filament glass fiber mat which comprises about 40% of the weight of the resinuous material. Thermoplastic fittings are used to coupled water conduits to the tank.

Abstract: An instrument panel for an automobile is provided comprising a beam member. The central portion of the beam is spaced away from the frame and is capable of flexing elastically in the transverse direction. A recoil restraint means is secured at one end intermediate the ends of the beam and is secured at the other end to the frame. The recoil restraint means permits motion of the beam in the transverse direction towards the frame but preventing motion away from the frame.

Abstract: A rotor assembly includes a flux ring comprising a generally cylindrical ring of magnetic flux conducting material. A plurality of circumferentially spaced reinforcing ribs are fastened to the ring, each of the ribs projecting radially outward of the ring and extending axially for substantially the length thereof. A separate body of magnetic material is fastened to the ring between each adjacent pair of ribs. A method of manufacturing the flux ring is implemented by first providing a substantially flat sheet of magnetic flux conducting material. The sheet is bent to form a plurality of reinforcing ribs thereon, and subsequently rolled to form a cylinder with the ribs projecting radially outwardly thereof.

Abstract: A displacement transducer is used to continuously monitor the distance between two fixtures securing parts to be welded. The signal from the displacement transducer is used to stop the welding process when a desired amount of material has been extruded from the weld. The control strategy will automatically take into account part nonuniformities that normally result in poor welds in welding processes that use time as the control variable.

Abstract: A disc rotor assembly includes a ring of magnetic flux conducting material having a ring-shaped magnetizable body fastened thereon. The magnetizable body includes a flat, axially facing, ring-shaped rotor surface for opposing a stator in an electric motor. The disc rotor assembly further includes a shaft disposed coaxially therewith, and a matrix molded between the ring and the shaft.

Abstract: A rotor assembly includes a flux ring comprising a generally cylindrical ring of magnetic flux conducting material. A plurality of circumferentially spaced reinforcing ribs are fastened to the ring, each of the ribs projecting radially outward of the ring and extending axially for substantially the length thereof. A separate body of magnetic material is fastened to the ring between each adjacent pair of ribs.

Abstract: A magnet assembly having means for reducing release of magnet material particles from the magnet element includes a body of permanently magnetizable material and a shell at least partially surrounding the body. The shell is disposed and located so as to reduce release of particles shed from the surface portion of the body which is surrounded by the shell, and is preferably attached to the body by an adhesive which bonds the adjacent surfaces of the shell and the body together. A plurality of such magnet assemblies may be fastened to a flux ring in order to provide a rotatable assembly for a dynamoelectric machine in which migration of magnet material particles into the stator-rotor air gap is reduced. In accordance with a preferred embodiment, the magnet assemblies of the present invention are employed in a molded rotor assembly for such a machine.

Abstract: A rotor assembly particularly suited for use in oscillating electric motors includes magnet assemblies mounted on stiffening rings. The stiffening rings and magnet assemblies are bonded together by an intermediately disposed matrix. Each stiffening ring includes at least two radially outwardly extending tangs, the tangs separating adjacent pairs of magnet assemblies. In operation, these tangs function to support the magnet assemblies, particularly against cyclic fatigue loads developed in oscillating electric motors.

Abstract: A magnet assembly having means for reducing release of magnet material particles from the magnet element includes a body of permanently magnetizable material and a shell at least partially surrounding the body. The shell is disposed and located so as to reduce release of particles shed from the surface portion of the body which is surrounded by the shell, and is preferably attached to the body by an adhesive which bonds the adjacent surfaces of the shell and the body together. A plurality of such magnet assemblies may be fastened to a flux ring in order to provide a rotatable assembly for a dynamoelectric machine in which migration of magnet material particles into the stator-rotor air gap is reduced. In accordance with a preferred embodiment, the magnet assemblies of the present invention are employed in a molded rotor assembly for such a machine.

Abstract: A disc rotor assembly includes a ring of magnetic flux conducting material having a ring-shaped magnetizable body fastened thereon. The magnetizable body includes a flat, axially facing, ring-shaped rotor surface for opposing a stator in an electric motor. The disc rotor assembly further includes a shaft disposed coaxially therewith, and a matrix molded between the ring and the shaft.

Abstract: A rotor assembly particularly suited for use in oscillating electric motors includes magnet assemblies mounted on stiffening rings. The stiffening rings and magnet assemblies are bonded together by an intermediately disposed matrix. Each stiffening ring includes at least two radially outwardly extending tangs, the tangs separating adjacent pairs of magnet assemblies. In operation, these tangs function to support the magnet assemblies, particularly against cyclic fatigue loads developed in oscillating electric motors.

Abstract: A molded commutator is made up of segments arranged in a ring with their brush contact surfaces facing inwardly and forming a cylindrical shape. A matrix of plastic is molded between and around the outside of the segment ring in order to separate the segments electrically and to hold them in the ring configuration. A reinforcing metal casing serves to contain the commutator against breaking up due to centrifugal forces experienced during rotation. An alternate embodiment uses metal bands embedded within the matrix for this purpose.

Abstract: A plastic end shield for use in a dynamoelectric machine of the type having a rotor assembly rotatably disposed in a housing includes an end plate for attachment to the housing, so as to provide structural support for one end of the rotor assembly, and a thermal barrier adjacent to the end plate for thermally insulating the end plate from heat generated inside the housing. In a preferred embodiment, radial and circumferential support members and axial and circumferential reinforcing ribs are employed in order to efficiently utilize the plastic material. The thermal barrier may be provided with a plurality of vent openings through which heat generated inside the housing can escape from the housing and the end plate. Means employed to attach the end plate and thermal barrier to the housing may include a thermally insulative material which prevents heat from being conducted from the housing to the end plate.

Abstract: A method of making a rotor for a dynamoelectric machine comprises the steps of forming a plurality of flux ring segments of flux conducting material. Segments of magnetizable material are then secured to each of the flux ring segments to form a ring-segment magnetizable material subassembly. A plurality of subassemblies are situated in a cylindrically shaped molding ring, with the magnetizable material adjacent to the inside walls of the molding ring. A shaft is situated in the molding ring along the axis of the cylindrical molding ring. A plastic material is molded around the shaft and inside the ring-segment-magnetizable material subassemblies whereby the outermost surfaces of the magnet material define a cylinder.

Abstract: A rotatable assembly for a dynamoelectric machine has a pair of sets of opposite tabs formed on a flux ring at least adjacent a pair of opposite end portions thereof, respectively, and a set of magnet material elements is disposed in assembly positions generally about an outer circumference of the flux ring. At least some of the opposite tabs are deformed into engagement with confronting parts of the magnet material elements in their assembly positions, and thereby at least in part, the magnet material elements are retained against displacement from their assembly positions.

Abstract: A molded commutator has conductive segments circumferentially arranged about a central axis so that their outer surfaces form an overall structure of cylindrical shape as the outer surface of the commutator. Inside of this structure is an annular core to which each commutator segment is anchored by a tang formed on the inner surface of each segment, which is mechanically interlocked with a pair of tangs on the core. The tangs are shaped and configured such that, after assembly, each segment tang is interlocked between the core tangs in a dove-tail-like relationship. A nonconductive matrix is molded between the segments and the core. A method of making the commutator is to form an annular segment pack containing the conductive segments, with each segment having a segment tang formed on its inner surface, and an annular core having the core tang for one axial end of the commutator formed on its outer surface.

Abstract: A bumper for a vehicle is provided with an inner beam member. Two longitudinally separated bumper supports affix the inner beam member to the vehicle. An outer beam member having interbeam support means positioned longitudinally displaced from the bumper supports affixes the outer beam member to the inner beam member in a spaced apart relationship. The interbeam supports and the bumper supports do not align in the transverse plane of the beam member. The outer beam member sustains the initial impact force in a collision.

Abstract: A plastic support for attaching a plastic bumper to the metal frame of a motor vehicle comprises a metal pad having means for attaching the pad to the metal vehicle frame. The means for attaching the pad extends from, and is affixed to, one face of the pad. The pad is completely embedded in a moldable thermoplastic matrix except where the means for attaching the pad to the metal vehicle frame extends through the matrix. The matrix adjacent the other, or opposite, face of the pad is affixed to the plastic bumper, forming a plastic-to-plastic joint.