Abstract: Apparatus and methods for partially embedding a biocompatible material, such as a titanium coil, in the surface of a polymer bone implant to provide a porous coating for bone cells to grow through thereby promoting long term stabilization of the implant. In one embodiment, the coil is wrapped around the implant and placed in a manifold where rollers biased by springs press against the coil. The coil-implant is rotated and heated by a hot gas stream, the rollers-springs pushing the coil into the surface of the implant. In a second embodiment, the coil is compressed and placed onto a needle wire which is placed against the surface of the implant. The point of contact is heated and the implant is rotated with the needle wire creating a channel in the softened polymer and feeding the coil, which is simultaneously stretched, therein. The needle wire then pulls the polymer over a portion of the coil as it passes.

Abstract: A process for manufacturing wire or needles having a taper point and mechanically drilled suture mounting holes in the proximal ends. Needle or wire blanks are cut from a roll of wire and mounted to a carrier strip. The carrier strip and needles are moved through a succession of forming and trimming and grinding stations. The blanks are coined in a coining die to produce lateral wings of constant thickness. The blanks are preferably rotated in the strip while being ground. The strip and needle blanks are then moved to a bank of at least two drills wherein the proximal suture mounting ends of the needles are drilled.

Abstract: A needle cannula with a first end and a second end wherein a section near said second end must be shaped into a coiled spring and then pulled into a biased spring needle cannula without destorting the inside surface of said spring needle cannula. A wire of suitable section is inserted into said cannula of said spring needle cannula and wherein said first end of said spring needle cannula is inserted into a hole formed in a retainer plate and wherein a portion of said spring needle cannula with said wire in said cannula is wrapped or coiled about a coil bar wherein said needle cannula is formed into a spring needle cannula and wherein the inside walls of said cannula cannot deform due to said wire disposed in said cannula.

Abstract: A base metal repair tape includes a first layer formed braze alloy bonded together with fibrillated polytetrafluoroethylene, a second layer formed from powdered base metal comprising oxygen-sensitive superalloy bonded together by fibrillated polytetrafluoroethylene and a third layer comprising a brazing alloy bonded together by fibrillated polytetrafluoroethylene. This is used to repair base metal by placing the first layer on the base metal and brazing the base metal powder so that the brazing alloy melts and diffuses into the base metal powder bonding it to the surface of the article. This permits the braze powder to be bonded to the base metal surface with minimal distance between the base powder particles. The number of alternating layers of base metal and braze alloy can be increased to increase the thickness of the repair. This can also be used to form small intricate parts.

Abstract: A method and apparatus is provided for connecting area grid array semiconductor chips to a printed wire board. A compliant lead matrix includes a carrier and a plurality of conductive leads arranged parallel to one another and secured relative to the carrier in the form of a matrix. The method includes orienting a first side of the lead matrix to be aligned with a reciprocal matrix of conductive surface pads on the area grid array semiconductor chip. First ends of the leads are electrically connected to the conductive surface pads of the area grid array chip. The second side of the lead matrix is oriented to be aligned with a reciprocal matrix of conductive surface pads on a printed wire board. Second ends of the leads of the lead matrix are electrically connected to the conductive surface pads of the printed wire board thereby establishing an electrical connection between the area grid array chip and the printed wire board.

Abstract: A protective coating is applied on a local region of a surface of a component on which direct deposit of a uniform coating of protective material is impeded due to a complex shape of the region to be covered or inaccessibility or inability to apply a uniform deposition or electrical field therefor. The coating is formed by a foil having a solder backing layer with a thin layer of uniform thickness of the protective material electrolytically deposited on the backing layer, the foil being cut to size corresponding to an area of the local region of the component to be protected. The cut to size foil is positioned and held on the local region of the component to be protected; and fixed in place by melting the solder to fuse the foil to the component and cover the local region.

Abstract: A honeycomb extrusion die and a method of making the die are disclosed, the die being made by bonding a die discharge section formed as a separate pin array to a separate die body incorporating an array of feed channels, the pin array comprising a plurality of pins attached to and extending outwardly from a body-compatible pin support which is removed after bonding the pins to the body. The pins may be formed of hard wear materials, and may have any of a variety of cross-sectional shapes adapted to improve extrusion uniformity as well as to form honeycomb cells of a variety of different cross-sectional shapes.

Abstract: A removable body for an electrical connector assembly. An electrical connector assembly includes a removable body and a plurality of substantially uniformly spaced pins or leads engaged thereto. The removable body includes a pair of oppositely opposed lever arms, biased in a first position, each lever arm including at least one abutment member and a gripping element. The removable body may also include a plurality of struts disposed between the lever arms and rotatably engaged at each end to a respective one of the lever arms. The removable body also includes a tee section diposed between the lever arms. The tee section includes a flange portion supported by the abutment members, and a web portion disposed between the abutment members. The flanges define a plurality of substantially uniformly spaced holes for receiving the pins. The pins are frictionally engaged to the web portion by the abutment members when the lever arms are in the first position.

Abstract: A method for temporarily connecting a body half and a door half of a hinge, said body half of said hinge including connecting means for receiving said door half of said hinge including connecting means for receiving the body half, one of said connecting means including a portion having disposed proximate the end thereof at least one groove for receiving a resilient flexible retainer;said method including the steps of;(a) fastening the hinge when assembled to a vehicle and a door so as to fasten the door with the vehicle temporarily;(b) painting the vehicle and door together while temporarily connected;(c) subjecting the vehicle and door and the resilient flexible retainer to heat such as that found in a curing process for a painting process for vehicles;(d) separating said body and door halves of said hinge by removing the retainer and separating said halves;(e) separating said door from said vehicle by separating the body half and the door half of said hinges.

Abstract: A method for applying a corrosion-protective coating, with a heat-shrinkable tube, to a joint between welded end portions of corrosion-protectively coated steel pipes, has a configuration comprising the steps of: preparing a coating implement having a releasant layer formed on the outer circumferential portion of the heat-shrinkable tube, and a heating layer formed on the outer circumferential portion of the releasant layer; positioning the coating implement so as to cover the welded portion of the joint and its adjacent portions; thermally shrinking the coating implement in a state in which the gap between the coating implement and the aforementioned portions is kept in a vacuum; and removing the releasant layer and the heating layer, whereby the aforementioned portions are corrosion-protectively coated by the heat shrinkage of the tube.

Abstract: A method for manufacturing a titanium alloy sheet, which comprises the steps of: covering at least one titanium alloy slab with carbon steel plates, welding together the carbon steel plates by means of a high-energy-density welding under a vacuum atmosphere to prepare a carbon steel envelope, thereby preparing an assembled slab, containing the titanium alloy slab therein, with an interior thereof kept at a degree of vacuum of up to 10.sup.-2 ; applying, prior to preparation of the assembled slab, a release agent comprising a solid content having a particle size of up to 325 mesh, onto the surfaces of the titanium alloy slab or onto the inner surfaces of the carbon steel envelope facing thereto, adjusting the total applying quantity of the release agent so as to satisfy the following formula: 5,000.ltoreq.X.multidot.Y/(1-.sqroot. Z).ltoreq.25,000, where X: weight percentage (wt. %) of the solid content in the release agent, Y: total applying quantity (ml/m.sup.

Abstract: A method of producing a tape-shaped superconducting wire is provided. The wire maintains a high critical temperature and a high critical current density along the overall length thereof. In this method, raw material powder for the oxide superconductor is first charged in a silver sheath and the sheath charged with the powder is subjected to plastic working to prepare a first flat type wire. On the other hand, a second wire consisting of a tape wire formed by coating a surface of a flat type wire having at least an outer surface consisting essentially of silver or a silver alloy with a metal oxide or ceramics, or a tape wire containing ceramics fibers and a binder dissipated by heat treatment is prepared. The first and second wires are layered with each other, and tightly wound in a pancake coil shape. The wires wound in the pancake coil shape are heat treated for sintering the oxide superconductor. After the heat treatment, the first wire is separated from the second wire.

Abstract: A method of producing components, which include a metal film on a carrier, comprises the following steps: applying a metal film to a first carrier; structuring the metal film; reducing an adherence between the first carrier and the metal film by electrically conductive contacting of the metal film; immersing the first carrier with the metal film in an aqueous electrolyte solution; immersing an electrode in the aqueous electrolyte solution; and applying a voltage between the metal film and the electrode; applying a second carrier to the metal film; and removing the second carrier with the metal film from the first carrier.

Abstract: A process for making fine metallic fibers comprising coating a plurality of metallic wires with a coating material. The plurality of metallic wires are jacketed with a tube for providing a cladding. The cladding is drawn for reducing the outer diameter thereof. The cladding is removed to provide a remainder comprising the coating material with the plurality of metallic wires contained therein. The remainder is drawn for reducing the diameter thereof and for reducing the corresponding diameter of the plurality of metallic wires contained therein. The coating material is removed for providing the plurality of fine metallic fibers.

Abstract: Apparatus and methods for partially embedding a biocompatible material, such as a titanium coil, in the surface of a polymer bone implant to provide a porous coating for bone cells to grow through thereby promoting long term stabilization of the implant. In one embodiment, the coil is wrapped around the implant and placed in a manifold where rollers biased by springs press against the coil. The coil-implant is rotated and heated by a hot gas stream, the rollers-springs pushing the coil into the surface of the implant. In a second embodiment, the coil is compressed and placed onto a needle wire which is placed against the surface of the implant. The point of contact is heated and the implant is rotated with the needle wire creating a channel in the softened polymer and feeding the coil, which is simultaneously stretched, therein. The needle wire then pulls the polymer over a portion of the coil as it passes.

Abstract: A penetration seal (12) is provided including a flexible patch (14) having adhesive (20) applied to one of the patch's first and second face surfaces (16), (18). An opening (22) is formed in the patch (14) of a size predetermined to fit a particular penetration (24). The opening (22) is slightly smaller than the cross-sectional shape of the penetration (24). In addition, a method of sealing the space (28) between an aircraft penetration (24) and surrounding insulation material (26) is provided. The method includes providing a seal (12) having a patch (14) with first and second face surfaces (16), (18), an opening (22) in the patch (14), and adhesive (20) applied to the first face surface (16). The method further includes applying the patch (14) to the penetration and insulation material by passing the penetration (24) through the opening (22) at the first face and pressing the first face surface (16) to the insulation material (26).

Abstract: A reusable plug device for providing sealing of an opening of a rim of a wheel for leak testing has a simple structure and facilitates installation/removal of the plug device using a simple insertion tool and a removal tool. The plug body has an axially extending cavity for receiving the insertion tool to enable the plug body to be inserted until a flange section of the plug body abuts the surface of the workpiece. The flange section serves as a stopper to indicate the stop position and ensures a uniform installation of the plug device in each workpiece. For removal of the plug body, the removal tool is inserted into the cavity and the removal tool is pushed in the insertion direction, so that the plug body and the flange section both collapse inward into the cavity to enable the plug device to be simply pushed out through the opening section.

Abstract: A method of joining successive sections of tubular members having substantially dissimilar flexibilities is involved that includes the step of providing a transitional zone intermediate said successive sections having a flexibility intermediate those of the successive sections. Articles made by the process are also disclosed.

Abstract: A plurality of holes 2, each of which permits insertion of a small-diameter of an article to be manufactured, are formed in a flexible metal retaining plate 1 having a thickness of about 100 micrometers. A pair of notches 3, 3 are formed in the internal periphery of each hole 2 so as to be opposite to each other, and a cantilever 4 is defined between a pair of the notches 3, 3. The small-diameter portion of the article to be manufactured is inserted into each hole 2, and the cantilevers 4 and the hole 2 are integrally fixed together by welding. A plurality of the articles to be manufactured retained by the retaining plate 1 are fed as a unit to a surface abrasion step, a film-forming step, and others. As a result, a plurality of sensor elements can be simultaneously manufactured.

Abstract: A method and an apparatus for swaging a metallic embossed pipe to form concavities in its wall units, wherein, a die core made from a holding pipe having surface meshes and a plastisol filler is provided in the metallic pipe mounted in a circularly swaging apparatus having two positioning seats respectively movably provided on two ends of a slide way and can absorb swaging pressure exerted on the pipe wall, some swage processing seats movably provided between the positioning seats clamp the embossed pipe and position it accurately in an axis line; the processing seats press synchronically inwardly in a radiant array to swage the embossed pipe, thus the concaved pipe wall units are formed, the pipe hole and the die core are then slightly heated to draw the holding pipe and plastisol out to complete the process for swaging and forming the concaved wall units.

Abstract: A process for assembling a linear motion bearing using a retainerless saddle assembly. Such retainerless saddle assembly is composed of a bearing body having escape-ball through holes, steel balls, and a pair of end caps.

Abstract: An outer ring of an axle bearing is heat-treated and a through hole can be formed quickly and reliably. The outer ring has raceways on its inner periphery along which rolling elements roll. A through hole for mounting an antilock brake sensor is formed in the outer ring to extend from its outer periphery to the inner periphery. A plug is inserted into the hole thus formed. After hardening the raceways, the plug is pulled out of the hole. Since the hole is formed before hardening the raceways, it can be formed easily by drilling with an ordinary carbon steel tool. Since the raceways are hardened after inserting the rod-shaped metal plug into the hole 9, the heat produced during hardening will disperse through the plug. It is thus possible to prevent shoulder portions of the raceways from melting due to overheating.

Abstract: The present invention comprises a harmonic drive transmission assembly for use in contamination free manufacturing fields such as computer chip making. The harmonic drive unit includes a flexspline having a diaphragm at one end and an outwardly flared lip adjacent its other end which is integrally connected to a mounting flange. The flexspline including the diaphragm and mounting flange are all integral with one another, all being machined from a single piece of steel bar stock.

Abstract: A thin flat panel display is formed from two substrates uniformly spaced apart by a plurality of spacer members. The spacer members are formed into bundles, held together by binder material, and sliced into a plurality of thin discs. One opposing face of one of the substrates is provided with patterned arrays of first and second arrays of different adhesives. The discs are placed on the adhesives and processed to activate the adhesives, remove the binder and the second adhesive thereby reducing the number of spacers remaining in the assembly to only those adhered by the first adhesive. The second substrate is then juxtapositioned on the first substrate assembly and bonded thereto.

Abstract: To produce an elongate hollow metal body with a cross-sectional contour varying in the longitudinal direction by the internal high-pressure forming process in an internal high-pressure forming press, a sheet-metal blank composed of two blank parts of identical area is first produced, each part having, apart from additional joining-area parts provided in the region of the longitudinal edges, in the longitudinal direction at least the length of the longitudinal hollow body and in the transverse direction at most half the length of the respective cross-sectional contour. Subsequently, the two blank parts are laid one on top of the other and are joined together, in particular welded, in the region of the joining-area parts. Thereafter, the sheet-metal blank is expanded by introducing a pressure medium between the two blank parts held within a tool consisting of two dies.

Abstract: A seamless metal tube is made by elongating an assembly of a tube blank and a metal core by mechanical working, and then stretching the core plastically so that it diminishes in diameter sufficiently to permit its removal from the tube. The core metal is preferably a shape memory alloy.

Abstract: A process for manufacturing wire or needles having a taper point. Needle or wire blanks are cut from a roll of wire and mounted to a carrier strip. The carrier strip and needles are moved through a succession of forming and trimming and grinding stations. The blanks are preferably rotated in the strip while being ground.

Abstract: A method of shaping printed circuit boards comprises the steps of providing a base plate, installing a board shaped element including the parts to be shaped on an upper surface of the base plate, fixing the base plate and board shaped element on a table of a machine tool with a lower surface of the base plate in contact with the table, drilling a hole through the board shaped element within the contour of each part to be shaped, the hole extending substantially as far as the lower surface, installing a pin in the hole, carrying out the shaping of the parts, and, machining the pin to partially or completely remove the pin.

Abstract: A folded air bag retaining apparatus for retaining a folded air bag coupled to a reaction plate in a folded configuration during the positioning of a cover. The apparatus including a holding fixture for supporting the reaction plate and the folded air bag coupled to the reaction plate, in a position to receive the enclosing cover, and a flexible band for retaining the folded air bag in a folded configuration until after the enclosing cover is positioned to enclose the folded air bag and the enclosing cover is coupled to the reaction plate.

Abstract: A method is disclosed for manufacturing from a rigid single-wall tank having spindle members attached to and extending outwardly of each of its end portions a rigid double-wall tank for the storage of liquids. The method includes applying to the exterior surface of the inner tank a spacing material, applying over the inner tank and the spacing material an outer sheath with at least a portion of the outer sheath applied adjacent to each spindle member then removing at least one of the spindle members from the end portions of the inner tank and urging the outer sheath overlying the end portions away from the end portions to form a space between the end portion of the inner tank and the outer sheath, inserting into the spacing material and then sealing the end portion of the inner tank by applying a substantially liquid-tight sheath.

Abstract: A process for manufacturing wire or needles having a taper point. Needle or wire blanks are cut from a roll of wire and mounted to a carrier strip. The carrier strip and needles are moved through a succession of forming and trimming and grinding stations. The blanks are preferably rotated in the strip while being ground.

Abstract: A parting compound in the form of a monolithic component (3a, 3b) is used in accordance with the invention for the hot forming of encased metal parts (2). This component consists of powder particles strengthened by sintering. The parting compound material is brittle at ambient temperature and at the deforming temperature of the metal parts is plastically deformable or free flowing in a highly viscous manner.

Abstract: A process for assembling a linear motion bearing using retainerless saddle assembly. The retainerless saddle assembly is composed of a bearing body having escape-ball through holes steel balls, a pair of end caps and a ball holder. The assembling process includes the steps of attaching one of the pair of end caps at one end surface of the bearing body; and providing raceways within the bearing body. The diameter of each of the raceways is slightly larger than that of each of the steel balls. The assembling process further includes the steps of feeding the steel balls into the raceways and escape-ball through holes in the bearing body; covering an open end of the bearing body by another one of the pair of end caps so as to form a saddle; and holding the balls between the bearing body and the ball holder.

Abstract: A rubber-like molded product with a support frame includes a support frame having a predetermined shape; a connecting member constituted by a thin film or connecting ribs and engaged with the support frame separably therefrom; and a rubber-like molded product formed integrally in a region of the connecting member in such a manner as to be capable of being cut off from the connecting member. In this rubber-like molded product with a support frame, the support frame, the connecting member, and the rubber-like molded product are formed integrally by press molding or injection molding. In the assembly process, only the rubber-like molded product is cut off from the support frame and the connecting member of the integrated rubber-like molded product with a support frame by means of a pushing jig, and is fitted in a groove formed in a predetermined portion of a fitted member.

Abstract: A steering column assembly for a motor vehicle includes a steering column shaft (1) mounted so that it can move rotatably inside a column body (2), and a restraining arrangement (5) for temporarily axially immobilizing the shaft within the body for fitting the assembly onto the rest of the structure of the vehicle, it being possible to move the restraining arrangement between an active immobilization position and a non-obstructing position. The restraining arrangement includes structure (10) for enabling a limited degree of axial movement of the shaft within the body when the arrangement is in the non-obstructing position.

Abstract: A piercing grommet which pierces an insulation blanket. A snap-on retainer slides over a spiked portion of the piercing grommet and snaps in place adjacent the bottom of the spike. The spike can then be removed. A seal is created by contact adhesive between the insulation blanket and the grommet in order to prevent moisture ingress.

Abstract: A process for encasing articles, particularly encasing cable splices, cable termination, a radially expanded tube made of a rubbery elastic material is positioned on the article. The tube is maintained in the expanded condition by a tension medium in the form of a plastic tube attached to the outer surface of the tube. The attachment between the surface of the tube and the tension medium is removed for the purpose of resetting the tube. The resetting is accomplished by cooling the plastic tube to a sub-ambient temperature thereby destroying the plastic tube.

Abstract: A flexible film-like member having conductive metals filled in tapered holes extending through the thickness is positioned such that the holes of the member face to respective pad patterns on a circuit board on which bumps are to be formed, the conductive metals are then heated and fused so that they are joined and transferred to the pad patterns on the circuit board, and the film-like member is then removed by heating or cleaning liquid.

Abstract: A process for manufacturing wire or needles having a taper point. Needle or wire blanks are cut from a roll of wire and mounted to a carrier strip. The carrier strip and needles are moved through a succession of forming and trimming and grinding stations. The blanks are preferably rotated in the strip while being ground.

Abstract: In order to define cavities for vibrating spaces in a chip-type piezoelectric-resonator, which is protected with resin so as to be capable of surface mounting, a mother substrate including a piezoelectric substrate and a plurality of piezoelectric resonance elements formed thereon is prepared, and upraised adhesive layers in the form of walls are provided on respective major surfaces of the mother substrate so as to enclose the vibrating region of the mother substrate. Mother sheets, which are provided with plural cover sheets, are arranged so as to cover both the major surfaces of the mother substrate, thereby defining cavities for vibrating spaces therebetween. Then, protective resin members are applied to cover both the major surfaces of the mother substrate, which in turn is divided to obtain a plurality of chip-type piezoelectric-resonators.

Abstract: A process is provided for forming spacers useful in large area displays. The process comprises steps of: forming bundles comprising fiber strands which are held together with a binder; slicing the bundles into slices; adhering the slices on an electrode plate of the display; and removing the binder.

Abstract: A process for manufacturing wire or needles having a taper point. Needle or wire blanks are cut from a roll of wire and mounted to a carrier strip. The carrier strip and needles are moved through a succession of forming and trimming and grinding stations. The blanks are preferably rotated in the strip while being ground.

Abstract: A knob and skirt assembly having a dial which can be calibrated relative to a control shaft and easily assembled in the proper position of alignment. The assembly includes a knob having a handle portion and hub portion. The knob portion has a control shaft receiving socket at the outer end thereof. The handle portion has an axially facing annular rim. At least one arcuate segment of teeth is formed on the annular rim. A disk shaped skirt has a central opening which fits over and receives the hub of the knob. A shallow well is formed in the skirt surrounding the central opening. Teeth formed in at least one arcuate segment are positioned in the well to mesh with the teeth on the annular rim. Ribs on the knob are heated and bent over against the skirt to fasten the knob to the skirt and to frictionally resist rotation of the hub and the skirt relative to each other until a predetermined rotational force is applied. An indexing notch is formed in the central opening of the skirt at the peripheral edge thereof.

Abstract: A preplugged nut is attachable to a vehicle panel for fastening a component to the vehicle panel. The nut has a body with an opening for receiving a bolt to fasten the component to the panel and a plug in the body opening sealing the opening to prevent ingress of moisture, dust, fumes and other contaminants to the panel through the body opening. A method for forming a vehicle panel with the preplugged fastener includes forming the vehicle panel, forming a nut having a body opening for receiving a bolt to fasten the bracket to the panel, forming a plug, inserting the plug into the body opening of the nut and plugging the body opening to thereby prevent ingress of contaminants through the panel to the body opening after the nut is installed, and fastening the nut to the vehicle panel with the bolt.

Abstract: A process for manufacturing an electromagnetically actuated fuel-injection valve with a connecting ring of a non-magnetic material hermetically and permanently installed between an internal pole and a valve sleeve designed separately from the internal pole. The process reduces the cost of manufacturing fuel-injection valves by avoiding costly operations involved in the fabrication and assembly of the highly precise individual structural elements and in producing the hermetic and permanent connections. A one-piece magnet body is formed with an internal pole and an outer valve sleeve joined by a base. Above the base, the internal pole and the valve sleeve are radially separated by an axially running ring opening. A solder member and a non-magnetic intermediate ring are inserted into the ring opening, and the intermediate ring is then soldered to the magnet body. The base is then removed, thereby separating the internal pole and the valve sleeve.

Abstract: An assembly includes a quick connect cartridge which is inserted into a port of a valve or manifold in a pneumatic system for coupling external fluid lines of the system to the valve or manifold. The components of the quick connect cartridge and the O-ring seal are mounted on the tubular shank of a plug. The plug is used as a shipping pin and is also used to install the components into a port of the valve or manifold. Normally, the plug is withdrawn from the port after the components are inserted in the port. If it is desired to keep the port closed after initial installation of the components, the plug may be retained in the port until it is time to connect the port. If it is desired to leave the port permanently closed, the plug remains in place. The plug can be an open plug allowing testing of the valve in which case a dust plug is provided for shipping puposes.

Abstract: Methods for and preforms for making fiber reinforced composites are disclosed. According to the invention, preforms which allow composites to be machined are provided. Also, preforms with a uniform debulking ratio are provided with non-uniform fiber placement. In addition, methods of forming composites have less material waste and allow more than one composite to be consolidated at one time.

Abstract: A current transformer device is formed on a ceramic substrate which is provided with a plurality of planar conductive tracks formed on a surface of the substrate where the conductive tracks extend substantially radially from an imaginary point on the surface of the substrate. A structure of permeable material is then tape cast or epitaxially formed by vapor deposition of a thick film of magnetic ceramic over the major portion of each of the conductive tracks to form a permeable toroidal core. A lead frame is then placed over the core and a plurality of metal conductors are soldered to each of the respective exposed ends of the metal conductive tracks on the substrate. The required electrical elements to complete the current transformer device are mounted to a second side of the ceramic substrate and electrically connected to the toroidal coil for powering and/or receiving signals therefrom.

Abstract: A method of fabricating thin-film magnetic recording heads or "sliders" employs the step of slicing a wafer containing like-oriented transducers into chunks, each chunk containing at least a minimum number of rows of transducers such that the amount of bow induced in the chunk is minimized. Following the chunk slice, one of two methods may be followed to yield precisely-lapped single rows of sliders. In the first method, the chunk is bonded to a rigid support piece at one end, and to a rigid carrier tool at the other. The row bonded to the carrier is then sliced away from the chunk and lapped while attached to the carrier. The steps of bonding, slicing, and lapping are then repeated for each row in the chunk. In the second method, the chunk is bonded to a rigid carrier tool at one end, and the row at the other end is then lapped and sliced off. The steps of lapping and slicing are repeated for each row in the chunk.

Abstract: In an improved process for fabricating thin film head sliders from a wafer on one face of which a plurality of electromagnetic devices are arranged in rows, a single-row is mechanically processed to form sliders while it remains an integral part of the wafer, or after it is bonded to a fixture under a condition which induces no bow on the bar. Alternatively, double-row bar sliced from the wafer is used for fabrication of sliders, wherein each single-row bar is mechanically processed while it remains an integral part of the double-row bar, or after it is bonded to a fixture as an integral part of a double-row bar followed by severance of the bonded double-row bar into two single-row bars. The process eliminates or materially reduces any inducement of bow of the bar, which is a serious cause of throat height control problem associated with the prior fabrication methods.