Abstract: An assembly method for a vehicle anti-theft key having an embedded resistor pellet is provided. The resistor pellet includes a flange at one end which abuts one side of the key blade when the opposed end of the pellet is inserted into a through opening formed in the shank portion of the key blade. With the resistor pellet loosely positioned within the through opening, a second flange is attached to the end of the pellet that was inserted through the through opening, thereby capturing the pellet within the through opening by the two opposed flanges. In one embodiment, the second flange is formed in place by employing a polymeric molding process, such as a thermoforming injection molding process. A handle for the key is efficiently formed substantially simultaneously with the second flange using the same polymeric molding process.

Abstract: An improved truck bed toolbox lid and a method of producing the same. The truck bed toolbox lid includes an outer metallic sheet layer comprising a generally rectangular top sheet member, a longitudinal front edge member, two lateral edge members and a longitudinal rear edge member. A metallic liner sheet member is disposed inside the top sheet member in edge contact abutment with beveled inside edges of the front and rear longitudinal edge members and the lateral edge members to create an internal cavity in which the liner is by stitch welding. One or more injection ports are provided through the liner sheet member through which a self-expanding and self-curing, relatively high-density, foam is injected. The stitch welded edge contacts leave non-welded, gas permeable junctions along the wedged cavity periphery at a funneled apex of the edge contacted boundary which facilitate expansion of the foam toward the outermost edges of the cavity.

Abstract: A chip mounting assembly is provided which includes a dielectric substrate having at least one integrated circuit (I/C) chip mounted thereon. An electrically conductive cover plate is in contact with all the chips with an electrically non-conducting thermally conducting adhesive. A stiffener member is provided which is mounted ante substrate and laterally spaced from the integrated circuit chip. At least one electrically conductive ground pad is formed an the substrate. The stiffener member has at least one through opening therein and electrically conductive adhesive extending through each opening and contacting the cover plate and each ground pad. The invention also provides a method of forming such an I/C chip assembly.

Abstract: A hydroformable frame element is formed from the combination of at least two elements. The at least two elements are designed with a partially overlapping region, with an annular space defined within the overlapping region. The annular space is filled with adhesive, which is then cured to bond the at least two elements together. The adhesive bond is designed to withstand the stresses caused by the hydroforming operation and to retain its strength so that the hydroformed article is then usable as a vehicular frame element.

Abstract: A wire rope and socket combination comprises a wire rope socket, a rope formed of strands of twisted wires extending into the wire rope socket, selected strands of the twisted wires being bent over 180 degrees within the wire rope socket to provide a selected breaking strength; and babbit securing the rope in the wire rope socket. A method of constructing a wire rope socket, the method comprising the steps of: bending selected strands of a rope formed of twisted wires over 180 degrees to form bent strands; inserting the rope and bended strands into a wire rope socket; and pouring molten babbitt into the wire rope socket to secure the rope in the wire rope socket.

Abstract: A method for manufacturing a welded cylinder is provided wherein a seal (such as an O-ring seal or a cured polymeric sealant) is disposed between the tube of a cylinder and its welded end plug. The seal is spaced away from the circumferential weld that joins the end plug to the cylinder to reduce the hoop stress in the tube adjacent the weld, thereby reducing the tensile stress at the weld joint.

Abstract: A method and apparatus hermetically sealing a fiber array block is described. In one embodiment, a fiber array plate is fabricated and an array of tapered holes formed therein. An adhering metal layer, such as a titanium, nickel and gold multilayer, is deposited upon the fiber array plate. A solder preform is positioned on the fiber array plate so that the array of holes in the solder preform corresponds to the array of holes in the array plate. Fibers having an adhering metal layer deposited thereon, are then inserted through the fiber array plate. The tapered holes make the fiber insertion process easier. The fiber array plate is then heated such that the solder preform melts causing the solder to fill any gaps between the fiber array plates and the fiber. When the solder cools a hermetic seal is formed while the fibers remain accurately positioned.

Abstract: A method of manufacturing a vehicle chassis and a vehicle chassis that is formed in modules with couplers for connecting extruded beams. The method includes extruding a plurality of beams and a plurality of couplers that are loosely assembled together to a fixture having locating pins that are received in pockets formed on the couplers and securing the beams and couplers together to form a chassis. The chassis includes a center chassis module to which the fire wall bulkhead and passenger compartment are secured, a drive train and front suspension module to which the engine transmission and front suspension are attached, a rear suspension module to which the rear suspension and gas tank are secured, and front and rear crush modules including the front and rear bumper assemblies, respectively. Couplers used in forming the chassis include a central portion having an outer wall and a plurality of inner walls extending inwardly from the outer wall to the pocket.

Abstract: A method for molding a molded substance to a substrate is provided. A substrate connected to a fixing portion by a connecting portion is prepared. The substrate is placed in a mold, wherein a portion of the fixing portion is protruding from the mold. The fixing portion is fixed by a fixing device outside the mold. Then, the molded substance covering the substrate is formed within the mold.

Abstract: The present invention provides an improved method of constructing a food display case. The construction techniques make use of a crimping tool which stitches together overlapping metal flange portions of the component display panel. The resulting stitched seams permit the rapid assembly of the non-glass structural components. In situ foaming of the spaces between the interior and exterior display walls, floor panels, and top panels, provides a rigid spaced connection between the adjacent panels and provides for the overall rigidity and increased strength of the resulting display case.

Abstract: A building panel constructed of a gypsum-cement-catalyst formulation molded in layers and including a rigid stud framework. The layers include surface layers, a fire resistant layer and an insulating layer, as well as reinforcement and building paper. A modified panel is molded in layers with structural strength provided by a grid providing spaced apart wire panels.

Abstract: Changing the contour of a recess (12) in a body of solid material to a revised contour wherein a pattern (24) is made having the revised contour and this pattern is placed in the recess with a curable plastic material (31). After the curable plastic material is hardened, the pattern is removed providing the revised contour (30) of the recess. The body of solid material can be a flow channel block.

Abstract: A method for repairing a composite material having an internal void includes identifying the location of the internal void and forming a single channel extending from a surface of the composite material to the internal void. The method further includes pulling a vacuum in the internal void and inserting a repair material through the channel into the internal void.

Abstract: The present invention discloses novel methods for producing raised and sculpted ornamentation or designs on metal, including metal pieces such as jewelry. Also disclosed are pieces of metal, including jewelry, produced by using the disclosed methods.

Abstract: A Silicon carbide-silicon matrix composite having improved oxidation resistance at high temperatures in dry or water-containing environments is provided. A method is given for sealing matrix cracks in situ in melt infiltrated silicon carbide-silicon matrix composites. The composite cracks are sealed by the addition of various additives, such as boron compounds, into the melt infiltrated silicon carbide-silicon matrix.

Abstract: Metal powder is filled in a through-hole of a base member and a base porous body is formed by bonding the metal powder with each other and by bonding the metal powder to the base member so that an end surface on a bearing surface of the metal powder filled in the through hole is dented toward a compressed gas supply surface and at least a part of end surface on the compressed gas supply surface of the metal powder filled in the through-hole is dented toward the bearing surface. Subsequently, surface layer powder having smaller diameter than the metal powder is filled in the recess on the bearing surface to form a surface layer porous material layer by bonding the surface layer powder with each other and by bonding the surface layer powder to the base porous body 12 and the base member 10. The bearing surface is finished by removing face layer of the surface porous material layer by machining.

Abstract: A method for manufacturing sealing tool comprising a socket (3) and a head (4) at one end and the other end of a linear element (2) respectively and a protrusion (11) for locking the head (4) in a head-insertion hole (10) of the socket (3), which comprises the steps in the mentioned sequence of fixing a core ball (13) and either the socket (3) or the head (4) to the linear element (2), cutting the linear element (2) at a point close to the core ball (13), pulling the linear element (2) to bring the core ball (13) to be set in a cavity (27) and filing a synthetic resin in the cavity (27) in a manner such that the core ball (13) and the socket (3) engageable with the head (4) are integrally formed.

Abstract: Apparatus and methods for processing work piece components in which a molten phase is produced by a local energy input from at least one of an electric arc, a jet of combustible gas, an electron plasma, and a laser beam. At least one transducer is included for imparting oscillations having a frequency above 15 kHz. The oscillations can be imparted to one or more of the components, the region of the molten phase, and/or to any filler material that is added to the region of the molten phase. The apparatus and methods can be used with known thermal soldering, welding and cutting methods to improve the quality of weld beads and cut edges that are formed, and to increase the processing rate.

Abstract: A hollow reinforced structural member has a bulkhead having a layer of thermally expanded resin disposed between opposed side walls. A sleeve is retained within the resin layer and is oriented perpendicular to the longitudinal axis of the reinforce structural member. The sleeve is an alignment with bolt holes in opposite sides of the reinforced structure such that a bolt can be inserted there through. A component can then be bolted to the reinforced structural member at the site of the reinforcement. The invention not only increases the strength of the part, but also reduces vibration and noise transmission.

Abstract: A method for reinforcing a selected portion of a structural part utilizes a flexible tube having a unexpanded, preferably thermally expandable resin sheath. The sheath may be limited to a selected region along the length of the flexible tube. The flexible tube is inserted through a curved passage and conforms to the geometry of the part to be reinforced. After the portion of the tube having the sheath reaches the desired location, the tube is secured in place. Upon heating, the resin expands to several times its original volume and fills the structural cavity only at that region.

Abstract: A refrigerator door assembly is mounted on a stationary frame of a refrigeration unit and comprises a door frame integrally molded about a thermo-pane in sealing relationship therewith. The door frame is hingedly mounted on the stationary frame of the refrigeration unit by a pair of upper and lower hinge pins. A torsion bar, integrally molded within the door frame and secured to one of the hinge pins, functions to constantly apply a closing force on the door frame to move the door assembly into sealing contact with the stationary frame of the refrigeration unit.

Abstract: A final closure sealing member and a method for hermetically sealing an opening, such as an electrolyte fill opening in an electrochemical cell or a battery, are disclosed. After a cell is fully assembled and filled with electrolyte, the present sealing member is force-fit into sealing registry with the electrolyte fill opening to form a secondary seal for the cell. PreferablY, an outwardly facing portion of the sealing member is flush or slightly recessed with the side wall surrounding the fill opening. Then, the outwardly facing portion is welded to the opening side wall to form a primary hermetic seal.

Abstract: A pumpable, thermoplastic desiccated mastic capable of desiccating a sealed insulating glass unit. The disclosed compositions comprise a defined resin component and a desiccant/adsorbent component comprising at least 20% by weight of the composition of a desiccant or moisture and volatile organic chemical adsorbing material. The said desiccant/adsorbent component being present in an amount less than the level which will cause the composition when tested as set forth in ASTM D-1238, Procedure B using a 1100 gram load and an 8 gram sample at 190.degree. C. to provide a melt flow time for a piston travel of 2.54 cm(1 inch) of more than 60 seconds.

Abstract: In an automatic transmission connector for interconnecting circuits provided inside and outside an automatic transmission, there are provided a plurality of terminals, a housing for receiving the terminals, and a rear holder engageable with the housing. The housing has a plurality of cavities for receiving the terminals, respectively, and the cavities are separated from one another in such a manner that the cavities communicate with one another through partially-notched wall portions. The housing has terminal passage holes into which the terminals are press-fitted, respectively. The rear holder has wall piece portions, and when the rear holder is engaged with the housing, the wall piece portions cooperate with notches, formed in the wall portions of the cavities, to separate the cavities from one another, and also retain the terminals within the respective cavities.

Abstract: An automotive interior trim panel has an outer flexible skin that overlies a rigid backing panel formed with a foam entry hole through which foam precursors are poured into a space between the skin and panel and they react and expand to generate a foam layer within the space. Tab projections are carried by the panel and extend into the foam space to at least partially cover the opening and provide rigid backing support for foam expanding in the region of the entry hole to control the density of the foam in this entry hole region such that it conforms more closely with the density of the immediate surrounding foam.

Abstract: A method may apply a lubricant material into a tube of a tubing and includes mold device having an annular port for extruding a material to form a tube. The mold device includes a passage for supplying a lubricant material into the tube, and includes an aperture for supplying an air to apply the lubricant material onto the inner peripheral surface of the tube. A flexible coil and a cover sleeve are then applied onto the tube for forming the tubing. The wire may then be easily engaged into the tube of the tubing by the lubricant material.

Abstract: A wear surface for helicopter shoes is constructed by forming a railed enclosure on a curved base plate, placing a mosaic of smooth-surfaced tungsten carbide blocks on the base plate within the enclosure, brazing the blocks to the plate and rails, and grinding the rails to form a smooth, edgeless transition between the wear surface and the plate surface.

Abstract: The present invention provides a method of forming a continuous one-piece structural porous metal (SPM) structure having a predetermined geometry. The method the invention includes the steps of preparing a metal billet comprising a metal core formed of a metal and a gas, and solid metal face sheets bonded to opposite sides of the metal core; placing the metal billet in a mold cavity having a predetermined geometry defined by opposing inner surfaces of the mold with at least one of the opposing inner surfaces contacting at least a portion of the metal billet and spaced apart from at least a portion of the metal billet; and heating the metal billet to expand the metal core to form the expanded metal structure.

Abstract: An under-dimensioned surface on metal tooling used in repetitive high temperature formation of parts is repaired by application of a metallic coating by use of a metal arc spray system. The under-dimensioned area is first roughened, and then is bordered by a raised template spaced a short distance above the surface of the tool by shims. Next the metal spray coating is applied, followed by machining of the metal coating to the proper dimensions of the tool.

Abstract: A connector for a composite pipe includes a male conical member to be inserted between inner and outer layers of the pipe. The outer layers have oppositely wound composite strips which are overlapped along the conical surface. The ends of the strips are braided and a cup located over the conical surface. A filler is injected between the cup and conical member to fill the voids formed between the overlapping strips.

Abstract: An extrusion die for forming a honeycomb structure such as a catalyst carrier of a catalytic converter for internal combustion engines is provided. The extrusion die includes material inlet ports and latticed slits. The slits are formed in a die base and have first inner walls leading to an outer surface of the die base and second inner walls leading to the material inlet ports, respectively. Metal-plated layers are formed on the first inner walls of the slits to define outlets of the die and have the width smaller than those of the second inner walls of the slits, respectively. This die structure facilities easy extrusion of the honeycomb structure made up by thin honeycomb walls with a smaller extrusion resistance.

Abstract: A composite rotor for caliper disc brakes and the like includes an outer friction portion having two ring sections, with a plurality of supports extending therebetween to fixedly interconnect the ring sections in a mutually parallel, spaced apart relationship defining a cavity therebetween. The ring sections have opposite friction surfaces which interface with associated friction members. The rotor also includes an inner hub portion having a central mounting section which mounts the same on a drive member, and a peripheral section cast into the cavity of the outer friction portion to integrally interconnect the inner hub and outer friction portions of the rotor with primarily mechanical bonds formed at an unfused interface.

Abstract: A high pressure metallization apparatus provides a chamber for enclosing or enveloping a substrate in a high pressure environment, and thereby extrude a film layer into any voids in the covers holes or trenches thereon. The high pressure is maintained in a pressure chamber, which is substantially enclosed within a vacuum chamber. The apparatus includes a positioning member which relatively rigidly positions the pressure chamber plugs during high pressure operations, and also allows separation of the plugs to enable pressure chamber access. The apparatus is configured for relatively rapid access to the internal components thereof, for rapid service and cleaning turnaround. Additionally, the chamber is configured to have minimal relative movement between the structural elements thereof, to reduce particle generation in the apparatus.

Abstract: A rotating gate feeder (1) for feeding substantially particulate material comprises a housing (2) and a rotor (3) and also an end cap (8) at each end of the housing. The invention is characterized in that a wear-resistant coating (6) is cast directly on to the inner wall (14) of the housing which faces towards the rotor (3). The inner wall (14) of the housing functions as an outer mold and a purpose-adapted core (15) is used as an inner mold. The housing (2) may be provided at certain points with release zones on the inner walls (14) which face towards the cast wear-resistant coating (6). One or more wear members (12) having greater wear resistance than the molding compound may be embedded therein.

Abstract: An internal metal stitching method for repairing cracks in concrete comprising the steps of cutting slots to facilitate metal stitching brackets installed in saw cuts every two feet and at alternating angles to the crack. The concrete is marked using a stitching bracket as a template for marking out the concrete saw cuts. The saw cuts are made in the concrete following the outline of the bracket. The first cut is made along the length of the large bracket and the second and third cuts are made near the ends of each large bracket to accommodate end brackets which when fitted resemble a double "t". The saw cuts are cleaned and dried, filled with a filler resin, and the metal brackets are inserted and are submerged to 1/4" below the concrete surface. The filler is smoothed out to a level flush with the concrete surface. Additional decorative surfaces may then be applied, such as ceramic tiles, carpeting, linoleum or paint. Various shaped metal stitching brackets and a bracket made of filler are also disclosed.

Abstract: A coating system and method for facilitating the cleaning of hydrodynamic bearings and their associated structure is effectuated by applying a surface energy lowering coating to selected portions of the bearing other than the surface tension seal producing gaps thereof prior to a lubricant fluid fill. The coating system and method of the present invention may also advantageously be utilized to produce a secondary barrier seal extending a relatively short distance within and adjoining the opening of the surface tension seal producing gaps.

Abstract: Composite golf club heads having high density inserts cast by investment casting of reactive metals such as titanium that result in a high degree of bonding between the head and the insert.

Abstract: In the manufacture of an electrofusion coupler, a winding of an electrical resistance heating wire is wound directly around a mandrel which comprises two parts providing respective ends of the mandrel. The mandrel supports electrically conducting terminal elements by means of supporting locations on the mandrel parts which form an integral part of the mandrel. The resistance wire wound around the mandrel is connected to the electrically conducting terminal elements. Subsequently a body of thermoplastics is molded around the mandrel to form the electrofusion coupler, and thereafter the mandrel parts are extracted axially from the electrofusion coupler from opposite ends, leaving the winding and terminal elements in place in the electrofusion coupler. In a variant, a thermoplastic preform is manufactured having electrically conducting terminal plates secured thereto, the preform having an electrical resistance heating wire wound therearound and secured to said terminal plates.

Abstract: A corrugated spiral pipe with a joint is formed by the steps of winding a seal material on thread portions of a pipe end of a spiral pipe, fitting a part of a cylindrical joint body to the pipe end so as to cover a portion on which the seal material has been wound, injecting a liquid foamable resin material through an injection hole and letting it foam, and filling a trough portion of the spiral pipe with the foamed resin material so as to make the spiral pipe watertight for coupling purposes. When the spiral pipe with the joint is coupled to another spiral pipe, a waterstop is forced into a trough portion of a pipe end portion of the latter pipe, an elastic seal ring is fitted onto an outer peripheral face of the latter pipe, and the pipe end of the latter pipe is forced into an outward protruded portion of the joint body.

Abstract: A pumpable, thermoplastic desiccated mastic capable of desiccating a sealed insulating glass unit.

Abstract: A discharging furnace and a filling furnace are disposed in three dimensions in the upper and lower positions of a filling and discharging furnace. A reservoir is provided in an inclined surface protruding toward the lower filling furnace. The reservoir includes a valve operatively connected thereto. A hot blast heated by a duct heater through a duct is mainly fed into the discharging furnace for further heating, while a remaining small portion of the hot blast is fed into the filling furnace for keeping the filling furnace warm. Inside the discharging furnace, a filling material filled in a bent workpiece is molten and discharged into the reservoir and when the valve is opened, the gathered filling material is filled into the inside of the workpiece which is carried by a filling carrier. The filling carrier is divided into three portions of a filling pallet, a carrier body and a sealing pallet, wherein the filling pallet is provided with a nozzle and the sealing pallet is provided with a seal member.

Abstract: A fixed angle rotor and method of manufacture of a fixed angle rotor has a frustum shaped rotor having rounded surfaces reinforced by filament tow windings against both vertical and horizontal forces generated during centrifugation. A so-called "high speed" rotor has a bottom composite disc, a top composite disc, and a frustum shaped hollow fiber reinforced molded insert between the respective discs having a stepped exterior surface. An "ultra speed" rotor has a bottom composite disc, a top composite disc, and composite discs therebetween defining a stepped exterior surface. In both cases, these exterior steps have surfaces which capture the windings to the exterior of the rotor. A first class of individual fiber windings about the rotor is applied having a vertical reinforcement component parallel to the spin axis and normal to the laminate layers.

Abstract: A hollow chair may hold an amount of weight due to a flowable material contained therein and may be joined to one or more chairs.

Abstract: A method and apparatus for identifying cast parts. A master is provided at least partially formed in the shape of a part to be cast. A slot is then milled into the master, the slot having a mouth and a base, and the slot having a "dovetail" cross-section so that the slot is wider at the base than at the mouth. An expandable plastic tag is inserted into the slot. The tag includes an identification surface with indicia formed thereon. Finally, the master and tag are heated, causing expansion of the tag within the slot to secure the tag within the slot. The tag includes a pair of tabs extending laterally therefrom to secure the tag in the slot prior to heat expansion of the tag.

Abstract: A method of encapsulating a crystal oscillator (100). First, a dielectric material is assembled or connected to the bottom side of a lead frame (102). Second, oscillator components including a piezoelectric element, capacitors and an integrated circuit are attached on the lead frame (104). Third, an epoxy dam is dispensed around the periphery of the oscillator component locations (106). Fourth, a encapsulant is dispensed within the epoxy dam to encapsulate the oscillator components (108). Fifth, the epoxy dam and encapsulant are cured (110). Thereafter, the oscillator is singulated from the lead frame and the leads are formed for mounting (112).

Abstract: A golf putting head is formed to include a recess cavity on its front face which preferably includes a raised perimeter bead. The insert is cast in place within the cavity with the perimeter bead allowing the insert to extend slightly beyond the club face. Once cured within the cavity, the insert perimeter bead and club face is finished to remove the perimeter bead and provide a smooth planar surface for the insert and the club face.

Abstract: A method for forming a gas-filled consolidated metal billet, involving preparing a metallic shell container, filling the shell with a metal core material and pressurized gas, and consolidating the shell and its contents to form the billet. The consolidated billet is further formed in the same manner as solid metal components by conventional wrought mill working technologies. After thus forming a shaped billet having a predetermined, desired geometry, it is subjected to a heat treatment that expands the gas trapped within the core, to produce in situ a metal body having an integral sandwich-type structure with a solid metal facing and a porous metal core.

Abstract: To manufacture a turbine wheel having blades made of a ceramic or composite material and inserted into a metal hub, firstly blades (16) are manufactured that are right cylindrical, each blade having a base (18) through which a hole is formed; a cylindrical ring (20) is formed, the ring being provided with orifices through which the bases (18) of the respective blades (16) are inserted; the blade bases (18) are successively threaded onto an open annular rigid metal wire (30); the resulting assembly (16, 20, 30) is disposed inside a sealed housing (161); hot isostatic compaction is performed so as to compact a metal alloy in powder form (41) inside the sealed housing (161) so as to make the hub of the turbine wheel (100) while embedding the blade bases (18) and the metal wire (30) by using the powder metallurgy technique; and the outside portion of the sealed housing (161) delimiting the hub of the turbine wheel (101) is machined. Application, in particular, to the field of aeronautical or space engineering.

Abstract: To reduce the need for manual work, improve productivity and reduce the fabrication cost in the method for molding a lead screw for converting a rotational movement into a linear movement, there are provided a method and a die assembly which may involve the steps of forming a plurality of holes in a wall of a tube in a spiral arrangement, preparing a metallic die assembly provided with a cavity defining a thread groove adapted to form the thread crest matching in position with an array of the holes, placing the tube in the cavity, and injecting synthetic resin material into the cavity so that the synthetic resin material may flow in two separate flows, one flowing inside the core tube, and the other flowing along the outer surface of the core tube. The thread crest is connected to the synthetic resin material filled in the core tube, and can be securely attached to the core tube. Optionally, an annular rotor may be fitted onto the base end portion of the lead screw.

Abstract: A novel, pumpable, thermoplastic desiccated mastic capable of desiccating a sealed insulating glass unit. The compositions utilize adhesive materials which have a low vapor transmission rate but, nevertheless, have been found to effectively dry the air space in the unit. They do not contribute to chemical fogging and, in preferred embodiments, reduce or eliminate chemical fogging caused by other structures in the assembly. The compositions adhere well to the U-channel material and do not flow or sag under the normal range of service conditions encountered by an insulating glass assembly.