Abstract: A method of manufacturing a brush seal for effecting a seal between relatively moving parts. Brush elements are first made by assembling bundles of bristle elements in holding tubes therefor, the brush elements then being mounted for instance by an adhesive on a carrier, so as to lie at the required disposition. The free end portions of the bristle elements are affixed to a brush seal root member, and the bristle elements are cut off at the required position between the root member and the carrier; the carrier and holding tubes--which may be re-used--are removed to leave the brush seal. A final machining of the brush seal, such as of the bristles, may be performed.

Abstract: A method for manufacturing a turbine rotor assembly from dissimilar materials to produce a hybrid composite rotor including the steps of: preforming a hub disc of a controlled outer diameter and prefabricating a ring of airfoils including a machine slotted fixture ring of mild steel slotted to receive airfoils inserted therein; and wherein the method further includes the steps of grinding the internal diameter of the mild steel ring to expose the airfoil bases to locate them at a radius line which will correspond to the outer diameter of the hub disc rim to maintain a pressure fit relationship therebetween when the ring of airfoils is pressed or shrunk on the outer diameter of the disc and thereafter sealing exterior joint lines between the mild steel fixture ring, airfoils and hub disc to form a pressure sealed surface on the exterior of the joined parts; subjecting the full outer planar extent of the pressure sealed configuration to an elevated pressure while maintaining it under an elevated temperature to

Abstract: There is disclosed a method and apparatus for the simultaneous machining of a stack of plate-like workpieces wherein the individual workpieces of the stack are initially assembled into a stack which is held in a manner which will not interfere with the subsequent machining operations by use of rivets or the like. The plate-like workpieces are mounted in the stack upon a support plate, and the machining operations are preferably so conducted as to penetrate through the lowermost member of the stack and into the upper portion of the support plate. The machine tool is preferably one in which a series of stations for drilling, riveting, machining and then drilling out the rivets is provided. The tool may include means for automatically and precisely moving the stack between the several work stations.

Abstract: A method of assembling a metal-clad rigid airship hull and apparatus for use in the assembly is disclosed. The apparatus is a rotating cradle consisting of an endless belt extending around and suspended between motor-driven cylinders. The cradle is rotated to provide angular positioning of hull surfaces of the airship at specific work locations. The bow and stern of the airship are assembled in a vertical position and, upon completion, are hoisted by a crane or sling to the horizontal position and attached to the main section of the airship hull structure utilizing the rotating cradle.

Abstract: Methods of forming a solid ion-conductive electrolyte are described which comprise providing a preformed thermoplastic polymer film, positioning a plurality of solid ion-conductive particles against one surface of the polymer film, positioning a deformable sheet against one surface of the film, positioning a deformable sheet against the particles and the opposite surface of the film, hot pressing the particles into the film and deforming the deformable sheets, cooling the film, and removing the deformed sheets, thereby forming a polymer film having ion-conductive particles exposed on opposite surfaces of the film.

Abstract: Thermoshrinkable or thermoexpansive tubes for corrosion prevention or lin of piping are disclosed which have their inner and/or outer walls covered with at least one protective cover to keep them clean from dust, dirt, water or any other foreign matter which might interfere with adhesion to the pipe connection, thus causing corrosion or poor lining.

Abstract: A method is provided for point rotation sawing of crystalline rod material at off-orientation angles wherein the crystalline rod is encapsulated in a molding media forming a cylindrical geometric encapsulation containing the rod with its crystallographic axis at an angle to the cylindrical axis of encapsulation, the angle coinciding with the off-orientation requirement. The encapsulation cylinder is rotated about its axis and contacted by sawing means at one or more points tangent to the cylinder surface and perpendicular to the cylinder's axis of rotation resulting in the sawing of a thin wafer from a cylinder which is inclusive of an off-orientation crystalline material wafer.

Abstract: A thin roller thrust bearing assembly including first and second annular races, an annular roller separator and a plurality of rolling elements is provided with a grease retained assembly, an outer banding cup or a combination thereof. In a purely grease retained assembly, a coating of tacky grease secures together first and second annular races with an annular roller separator and a plurality of rolling elements retained therebetween. The grease retained assembly provides a stable package for shipping and handling of the bearing. Alternately, an outer banding cup secures the first annular race and the annular roller separator with the rolling elements retained therebetween. In this case, the second annular race is secured to the annular roller separator and the rolling elements with a coating of tacky grease. Alternately, the outer banding cup encompasses both the first and second annular races with an annular roller separator and a plurality of rolling elements retained therebetween.

Abstract: A method for fabricating a filament reinforced metal matrix composite comprises bonding a plurality of filaments to a perforated metal foil with a fugitive binder, overlaying the filaments with a second perforated metal foil to form a stack, positioning the stack in a vacuum die, heating the stack in a vacuum to cause vaporization of the binder and evacuation of the vapors through the perforations in the foils and hot pressing to consolidate the stack.

Abstract: A method of and apparatus for uniformly debossing and perforating a ribbon of thermoplastic sheet material or film through the use of vacuum in combination with a flash heating source such as a flow of hot air. The apparatus causes a ribbon of such film to be forwarded from a supply such as a roll of thermoplastic material, then about a circumferentially extending portion of a rotating debossing-perforating cylinder, and then downstream where the debossed and perforated film may be further processed or where it may be wound on a spool to form a roll thereof. The debossing-perforating cylinder comprises a perforated tubular member through which a plurality of independently adjustable levels of vacuum can be applied from within the cylinder to circumferentially spaced sections of the film in contact with the exterior surface of the perforated tubular member. The apparatus further causes a virtual curtain of hot air to be directed radially inwardly towards a predetermined zone of the perforated tubular member.

Abstract: A method of making a socket contact by forming a slotted cylinder and pressing it beyond its yield point to effect an oval like socket. In engagement with a pin, the socket wall provides a highly efficient spring action which is capable of producing high insertion and removal forces.

Abstract: A method of manufacturing wire is described. "High performance" alloy rods in an "as cast" condition are incorporated into a filled billet which is extruded within defined extrusion parameters to obtain a simultaneous reduction in the diameters of the cast rods. After separation from the filled billet, the extruded "high performance" rods, now in wire form, are particularly suitable for manual welding applications of hard facing deposits. The separated "high performance" alloy wires are joined by butt welding to form a wire of indeterminable length which is accurately sized by successive drawing and annealing steps, making it suitable for use with an automatic welding machine to weld hard facing deposits. An optional second extrusion step is also described.

Abstract: The specification discloses a seat belt assembly having a plastic encapsulated, molded in place steel strap and a method for fabricating by vinyl dip-molding. Fabrication of the assembly includes forming an elongated, flattened structural member having a hole for connecting the structural member to a vehicle, securing a spacing block over the hole of the structural member and dip molding a resilient coating generally over the entire assembly. The coating is cut on three sides of the blocks to form a moveable, cupped flap permitting removal of the spacing block and exposing the hole so a coupling means can pass through the hole thereby connecting the seat belt assembly to the vehicle. After connection, the flap is returned to its original position encapsulating the structural member so the hole and coupling means are covered.

Abstract: The invention permits the lining of a passageway or pipeline with a resilient but robust, semi-rigid plastics pipe. The invention enables the lining of pipelines and passageways of long length by extruding the lining tube on site, deflecting the tube so that it is deflected into smaller diametral size, holding the tube in the deflected condition, feeding the deflected and held tube into the passageway to be lined, and releasing the hold on the tube so that it deflects or is deflected back to its original form and lines the pipeline or passageway.

Abstract: A process for producing mass filters for use in mass spectrometers. Several electrodes having precisely shaped surfaces must be held in precisely determined positions with respect to each other. Insulators are placed into position on the surface of a mandrel and a layer of metal is deposited over the mandrel and insulators to form a composite unitary structure, including the electrodes. The deposited metal overlying the insulators is then removed, electrically isolating the electrodes.

Abstract: A high performance heat pipe and the method for constructing it. A unique wick structure of sintered metal is formed directly into the heat pipe casing and contains simultaneously formed tunnels which permit the flow of large quantities of liquid with low pressure loss. A method of constructing a hybrid structure with heat pipe sections at both ends of a section used to transport the internal liquid and vapor over long distances is also included.

Abstract: An improved billet and process for producing a tubular body by forced plastic deformation is disclosed. The billet includes a metallic tubular sheath, a metallic center core and a salt intermediate core. The radial thickness of the metallic tubular sheath is equal to or less than 0.11 times the outer diameter of the metallic tubular sheath. The metallic center core is positioned within the tubular sheath and is surrounded by the salt intermediate core which fills the cylindrical space between the tubular sheath and the center core. In the process of the present invention, the foregoing billet is subjected to forced compulsory deformation to reduce the diameter of the billet. Thereafter, the intermediate core is removed through solution and the center core is drawn out of the sheath in order to obtain the tubular body.

Abstract: In the construction of a prestressed concrete structure, such as a bridge girder, forms for at least a part of the structure are built and a thin-walled sheathing tube is placed within the forms. Axially displaceable stiffener tubes extend through the sheathing tube. After the concrete is poured into the forms around the sheathing tube and sets, a steel bar is pushed through the sheathing tube and displaces the stiffener tubes. The steel bar can be left in the sheathing tube as the tendon or replaced with a tendon. Subsequently, the tendon is tensioned. Spacers encircling the steel bar keep it centered as it is pushed through the sheathing tube. Preferably, the stiffener tubes consist of an inner tube and an outer tube and each is made up of a plurality of short axially extending lengths with the joints of the inner tube staggered relative to the joints of the outer tube.

Abstract: An air inlet duct for a jet propulsion missile or other vehicle which is movable between a housed, pre-launch position and an extended or deployed flight position. A method of manufacturing the duct is also disclosed. The duct system includes a flexible leading edge attached to a double-wall inflatable duct body. Drop threads extend between the duct body walls to hold an exact desired contour when the duct is inflated. A pivotable plate moves the inflatable duct between a housed, deflated, position and an inflated flight position. Manufacture of the inflatable duct is basically accomplished by preparing a foamed plastic form in the desired duct wall shape, covering the form with fabric, stitching through the foam and fabric, coating the fabric with a flexible sealing compound, dissolving away the foamed plastic and attaching the resulting inflatable duct to other missile components.

Abstract: A method for forming a drive wire hole in a ferrite toroid phase shifter pted to operate in the millimeter frequency range. The ferrite toroid is fabricated by the arc plasma spray process. A slab of boron nitride is initially bonded to the dielectric insert of the ferrite toroid and the ferrite powder is arc plasma sprayed on the composite boron nitride-dielectric structure. The formed ferrite toroid is then annealed, and during the annealing process, the boron nitride slab is completely sublimated to form the required drive wire hole.

Abstract: A method of manufacturing a regeneratively cooled rocket combustion chamber which includes a thrust nozzle portion connected to a combustion chamber portion and which is constructed with cooling channels which extend in the longitudinal direction between an inner shell or wall having a smooth interior surface and an outer shell or wall and which are laterally bounded by radially extending webs, comprises forming the inner shell along with the cooling channel webs by electrodepositing metal on an electroplating core which is made up of chemically dissolvable material and has its outside contour conformable to the inside contour of the inner wall of the combustion chamber which is provided with radially extending projections forming mold blades for the webs defining the lateral boundaries of the cooling channels. Thereafter, the cooling channels are filled with a multiple electrically well-conducting filling material up to the level of the outer ends of the webs after these outer ends have been finish turned.

Abstract: An improved cable is provided having both the advantages of mass termination of flat cable and the flexibility of a cable with independent conductors for use in limited space situations. A plurality of substantially parallel and aligned insulated conductors is provided having a layer of flat backing material substantially covering the conductors. There is a layer of adhesive between the conductors and the backing. A further layer of a nonadhesive material is utilized over the adhesive so that the adhesive will not stick to itself in the event that the cable is bent. The adhesive bond between the conductors and the backing material is such that the backing is easily hand peeled from the conductors.

Abstract: A novel and improved method of forging preselected recessed surfaces in a member is disclosed which comprises the steps of adding a suitable lubricant material to at least a slave or primary preform member wherein the lubricant material is sufficient to prevent welding between the noted preforms during the forging operation. Moreover, the method envisions the step of joining the slave preform to the primary body preform member, followed by forging the joined together preforms such that the primary preform member is deformed to an extent generally complementary to a portion of the configuration of the slave preform, such that the forged primary preform has formed therein a shaped recess generally complementary to at least a portion of the configuration of the slave preform. It is contemplated that the forged slave and primary preforms are quenched subsequent to forging. Thereafter, the method contemplates removing the quenched slave preform from the primary preform.

Abstract: A frame and separator assembly for the manufacture of thin, flat laminar batteries in which the frame has adhesive surfaces to which a separator is adhered. The method of making batteries in which these assemblies are placed over electrode slurries extruded onto conductive plastic substrates and the separators are coated with electrolyte and then contacted with dry patch anodes on conductive plastic substrates to form cells.

Abstract: An interconnector for installation in an opening in a wall to provide at least one electrical connection through said wall, and a method for making same. The interconnector comprises a one piece tubular metal shell, at least one conductor within said shell, and two spaced apart glass sealing members supporting said conductors within said shell. The shell includes at least one port allowing access to the space interior of said shell and between said sealing members. The method for making the interconnector includes the steps of supporting one of the sealing members with a layer of inert flowable material, and subsequently removing the material through the port.

Abstract: A recoverable tubular article comprising an elastomeric sleeve held in a radially expanded or extended condition and capable of recovering to its pre-expanded condition of smaller diameter upon the removal of an outer restraint, an outer restraint, essentially tubular in configuration, bonded to said elastomeric sleeve, said bond between the sleeve and the restraint being sufficiently strong to retain the elastomeric sleeve in its expanded condition under ordinary conditions of storage and susceptible to attack by solvents weakening the bond sufficiently to allow the elastomeric sleeve to peel away from the restraint and recover to its original state.

Abstract: An orthodontic appliance, such as a plate, has means defining at least one opening therein, and an elongated wire-type member is provided having at least one end which is removably insertable in the opening of the first member. The elongated member has engaging means at an end thereof which resiliently deforms to lockingly and non-rotatably engage an inner surface portion of the opening which has means for releasably engaging the engaging means of the elongated member.

Abstract: A simplified and less expensive method for producing layer capacitors is disclosed in which an output capacitor is produced by winding several master or parent capacitors on a drum one upon the other. The parent capacitors are separated from one another by separating films of synthetic material. These separating films are then cemented to one another and to one of the parent capacitors lying underneath, but not to the parent capacitor lying above. Protruding portions of the separating layers are ground off. The portions of the separating layers remaining serve as protecting covering layers after the separation of the parent capacitors from one another.

Abstract: Pyrolytic carbon artificial socket prostheses for permanent or prolonged implantation in a living body, and methods for making such prostheses. The prostheses comprise a suitably shaped socket element substrate having a hemispherical socket cup, a compression-loaded hemispherical carbon shell mounted in said cup, and a vapor deposited carbon coating (including carbon-carbon alloys) on the substrate-carbon shell assembly.

Abstract: Process for winding and unwinding a parallel wire strand consisting of a multiplicity of individual wires onto and from a cable drum, and apparatus for performing such process. In the winding process, the parallel wire strand which is supplied in generally circular cross-sectional shape is fanned out so as to form a layer or layers of individual wires disposed in generally parallel position. The lead ends of the wires are anchored and such anchored end is mounted in a support therefor in the interior of the drum in such a manner that the subsequent winding of the individual wires in layers on the drum is without tension. In the unwinding operation, the individual wires are reformed into such circular cross-sectional strand shape at the bridge construction site, with corrosion-preventing material being applied to the individual wires during such unwinding, and a tubular casing of metal or plastic subsequently formed around the wires for sealing the same.

Abstract: A method of applying miniaturized high-temperature free-grid strain gauges to a test location by welding an auxiliary temporary backing to a strain gauge equipped with supporting or backing foil and connecting excess-length connecting webs thereto for manipulation of the gauge. Thereafter, the strain gauge is adhered, grid side facing downwardly, to a porous backing by means of an adhesive, the backing foil is then stripped off and the adhesive dissolved by a chemical solvent. The strain gauge is then applied to the test location and affixed thereto.

Abstract: This invention relates to a re-formable multiconductor flat, or ribbon, cable, which comprises a plurality of spaced insulated conductors, aligned in a predetermined, laterally spaced, pattern along a single sheet or film of plastic, the single sheet of plastic being only intermittently bonded to the laterally spaced conductors. The intermittent bonding pattern preferably utilized is one that results in transverse, peelably bonded, areas extending across the width of the entire cable alternating with transverse unbonded areas which also extend across the width of the entire cable.

Abstract: Wafers to be processed are mounted to a lapping plate of a lapping machine using a photosensitive thermoplastic material, such as a photoresist. In a preferred embodiment, the wafers are laminated to a dry film photopolymer disposed on a carrier sheet, after which the sheet is secured to the lapping plate using a pressed-fit hoop that stretches the carrier sheet across the surface of the lapping plate and holds the sheet secure about the perimeter of the plate.

Abstract: What follows is a description of a method of fabricating a composite assembly. In particular, the composite assembly comprises an aerodynamic rotor blade assembly which is fabricated utilizing a single matched die mold. Before utilizing the single matched die mold, the aft fairing structure of the composite blade assembly is formed. This aft fairing structure is uniquely characterized in that it includes not only the typical elements of an aft fairing structure of the composite blade, but the spar heel as well. The aft fairing structure thusly formed is then placed into the single matched die mold with the spar, nose block, cap member and deicing blanket, or with various subassemblies thereof, and the various parts brought into engagement and secured to each other in the single matched die mold through the application of heat and pressure.

Abstract: The invention provides ice skates and methods of making ice skates which have a body of a synthetic plastic material and a steel blade. The body includes an upper portion for attachment to the sole of a suitable boot and the blade has an upper portion enclosed in the body and a lower portion projecting from the body. The blade and body combine to define a localized and discrete anchor structure which locks the blade and body to one another, and the blade has a non-interfering upper surface. This surface allows the body to move freely other than at the anchor structure as the body moves longitudinally of the blade thereby limiting stress build-up in the body caused by shrinking. Mechanical fastening devices are used after shrinking to further hold the blade in the body.

Abstract: This invention relates to the making of negatives intended for the production of bodies which contain cavities of predetermined shapes.The term "negative" signifies a disposable core member, for example as used in some molding techniques such as the lost wax process. The negative at least partly matches the cavities which latter form two independent systems of regularly distributed intersecting channels with the channels in any one same system intercommunicating via ducts which are themselves regularly distributed.

Abstract: A highly accurate UHF television tuner utilizes an improved housing and an improved mounting system for securing the tuning rotor and stator within the housing. The housing is fabricated from sheet metal that is welded at the corners to provide mechanical rigidity, and soldered at the corners to provide a good electrical contact. A cover is placed over an open end of the housing and soldered at the corners further to increase the mechanical rigidity of the housing. The depth of the housing is increased to reduce the effects of the housing on the tuner elements. An eyelet is mounted in one end of the housing for supporting the rotor shaft, and the stator is mounted by insulating posts that are inserted through sleeves integrally formed in the housing. An improved contact for more effectively grounding the rotor shaft to the housing is provided, and an improved detenting system is provided for the selector shaft to reduce the effects of inertial creep.

Abstract: Through employment of a core-and-sheath construction having a number of axially elongated indentations along the border for the billet with the core of an easily soluble material, extrusion such as hydrostatic extrusion can advantageously be utilized for production of heat pipes with enhanced precision and operational efficiency in process. Indentations, which work as a wick in the heat pipe, may be provided by forming axially elongated grooves either in the inner peripheral surface of the sheath or in the outer peripheral surface of the core.

Abstract: A method of forming a composite structure having precision surface openings, such as an air foil through which air can be drawn in for boundary layer control. A metallic face sheet is bonded to a base member that is formed with elongate channels which are to serve as air plenums. A protective metal strip is inserted into each channel, and a high velocity water jet is directed against the face sheet at the area of each channel to form a through slot opening. The protective strip protects the base material from the inpact of the water after it passes through the slot being formed.

Abstract: Fine liquid particles having about the same size are provided by an atomizer tip which includes a wall member having a plurality of generally triangular conduits passing through it. Forcing liquid through the conduits under pressure causes the liquid to exit the conduits as an accurately controlled, small droplet size spray pattern. The wall member is formed from a billet including a number of concentric tubes having in their surfaces a plurality of generally V-shaped longitudinal grooves filled with complementary filler material. This billet is constrictively reduced and sliced into discs, and then the discs are domed and the filler material is removed. The thickness of the discs corresponds to the desired thickness of the wall member. Due to doming, the conduits diverge outwardly. The atomizer tip is adapted for use as a spray nozzle which provides greater uniformity in droplet size. Specifically, the atomizer tip is adapted for use in a fuel injector for an internal combustion engine.

Abstract: An improved method for transferring electrical components from a breadboard to a printed circuit board and mounting the components thereon is disclosed, as well as an apparatus for facilitating such transfer and mounting. In a preferred case, the breadboard comprises a solderless breadboard socket. A printed circuit board having a drilled hole pattern and circuit pattern matching that of a solderless breadboard socket is placed over the solderless breadboard socket so that the holes in each are aligned. Breadboarding is done by pushing the leads of various components through the printed circuit board and into the solderless breadboard socket. When the desired circuit is completed, the composite is utilized as one side of a container with the component side forming an inner surface thereof. Particles smaller than the components, such as polymer pellets, are introduced into the container to surround and cover the components and hold the components in place.

Abstract: This invention relates to the making of negatives intended for the production of bodies which contain cavities of predetermined shapes.The term "negative" signifies a disposable core member, for example as used in some molding techniques such as the lost wax process. The negative at least partly matches the cavities which latter form two independent systems of regularly distributed intersecting channels with the channels in any one same system intercommunicating via ducts which are themselves regularly distributed.

Abstract: An electric slider comprises a plurality of independently springing, aligned, uniformly spaced contact elements mechanically and electrically connected to one another. Each contact element is of elongated C shape having a discontinuity at one of its short sides. Each contact element comprises a base portion at which the contact element is connected to an adjoining contact element, a contact portion and a springing portion connecting the contact portion with the base portion. The contact portion is of circular cross section and at least part of the springing portion along a long side of the contact element is of flattened cross section. The plane of the flattened cross section is so oriented that the springing portion has, in the direction perpendicular to the slider motion, a moment of inertia that is larger than that of a circular cross section and, in the direction determining the resilient pressure, has a moment of inertia that is smaller than that of a circular cross section.

Abstract: A ceramic-metal composite laminate capable of exposure to high temperature differentials without damage, consisting of an inner ceramic layer, an outer metal layer and an intermediate interface layer of a low modulus metallic low density structure having a high melting point. The ceramic layer is secured to the low modulus structure directly or through an intermediate ceramic-metal composite, and the outer metal layer is brazed to the intermediate low modulus layer. Thermal strains caused by a temperature differential between the inner and outer layers are taken up without harmful effect by the intermediate low modulus layer.

Abstract: A method and an apparatus for manufacturing separable sliding clasp fasteners, from a continuous fastener having the interlocking elements made of thermoplastic material. The two male parts of the separating device of one fastener, the two top stops of another fastener, the support-strips reinforcements along these male parts and stops, and a opening for introducing a sliding clasp are simultaneously manufactured by: introducing the two uncoupled and spaced halves of a continuous fastener into a mold, injecting in the latter a melted thermoplastic material solidifying the thermoplastic material and cutting a part of the solidified material to form the said male parts, stops and opening. The apparatus comprises a mold consisting of a lower half-mold and an upper half-mold each comprising an outer fixed part and a central part perpendicularly movable to this fixed part.

Abstract: The invention provides ice skates and methods of making ice skates which have a body of a synthetic plastic material and a steel blade. The body includes an upper portion for attachment to the sole of a suitable boot and the blade has an upper portion enclosed in the body and a lower portion projecting from the body. The blade has a non-interfering upper surface which allows the body to move freely longitudinally of the blade during shrinking. This movement prevents build-up of residual stress in the body.

Abstract: A process for the continuous production of a hose formed and vulcanized on a mandrel, comprising continuously forming and advancing a hollow mandrel, continuously forming said hose about said mandrel and continuously vulcanizing said hose while advancing said hose in axial direction with said mandrel, after said mandrel arrives at a predetermined location continuously destroying said mandrel within said hose, and removing the remnants of said mandrel from said hose. The mandrel may be formed of a brittle material such as sintered metal or of a relatively low melting material and its destruction can be effected by longitudinal severance into strips and/or melting by induced current and/or fragmentation by ultrasound. Alternatively the mandrel may be made of soluble material and subsequently dissolved away. Endless reinforcements may also be circulated and the mandrel formed so as to partially embed said reinforcements. Corresponding apparatus is provided.

Abstract: A lightweight metallic honeycomb core panel structure having a high strength, a highly contoured surface and possessing relatively low thermal conductivity through the panel is prepared by bonding a first adhesive sheet and a peel-ply cloth to one edge surface of a honeycomb core prior to contouring the core into the desired shape with the first sheet applied to the surface which becomes the convex side of the panel. Sufficient force is applied to the sheet in order to force the edge of the honeycomb core through the uncured adhesive and the sheet is bonded to the core forming a structural fillet. The core is then contoured to the desired shape with the peel-ply acting to prevent spreading of node bonds at the convex surface. A second sheet also comprising an uncured adhesive material and a peel ply cloth is bonded onto the second side of the core so that a fillet is formed on the core cell walls. The peel-ply cloths are then removed to expose a bondable surface.

Abstract: An insulated door for refrigerators, freezers or similar cabinets where the inner and outer door surfaces are normally subjected to substantially different temperatures. The main door components, the door face and drum, are interconnected without the use of threaded fasteners such as screws or bolts. Instead a hardened, foamed in situ insulating material forms the main interconnection between the door face and drum, securing them together but yet accommodating thermally induced, relative movement between the two components. In constructing the door S-shaped retainers are used which receive in their oppositely opening loops the edges of the face and drum. Temporary spacers are then interposed between the face and drum edges for the foaming operation.

Abstract: A connector housing includes an electrical terminal attached to a carrier strip and an integrally-molded insulation housing over the terminal and carrier strip.