Abstract: A method for use in mass-producing, from a plane sheet of metal, a three-dimensional structure consisting of plane mirrors and plane structural members, said three-dimensional structure of a type in which each mirror or structural member has at least one edge that is collinear with an edge of another mirror or structural member, whereby said three-dimensional structure can be formed by bending the sheet of metal along various edges, the method including the steps of: producing masks bearing images defining the location of bending grooves, shallow grooves, separation grooves and holes for indexing pins, selecting a mask, applying a coating of photoresist to both sides of the sheet of metal, transferring the images on the selected mask to the coating of photoresist, removing those portions of the coating of photoresist to which the images were transferred, etching the sheet of metal where the portions of the coating of photoresist were removed, removing the remaining photoresist from the sheet of metal, and rep

Abstract: An echogenically enhanced medical device and method for manufacture are disclosed. A mask is applied to the surface of the medical device, and portions of bare metal are exposed through the mask. The masked device is subjected to a process which removes material from the exposed portions. The resulting depressions enhance echogenicity of the device under ultrasound. In a preferred embodiment the depressions comprise alternating rows of squares and diamonds disposed around the circumference of the device.

Abstract: A wiring board is fabricated through the following steps:(A) forming, on one side of an elongated carrier metal foil made of a first metal, a thin layer with a second metal whose etching conditions are different from those of the first metal;(B) forming, on a surface of the thin layer, a desired wiring pattern with a third metal whose etching conditions are different from those of the second metal;(C) superposing the carrier metal foil on an insulating substrate with the side of the wiring pattern being positioned inside, whereby the wiring pattern is embedded in the insulating substrate; and(D) etching off the carrier metal foil and the thin layer at desired parts thereof.

Abstract: A lead frame fabricating method and a lead frame fabricating apparatus are provided which can easily fabricate lead frames of fine pattern at a high speed, can improve dimensional accuracy and quality of the lead frames after the fabrication, and can realize mass-production at a lower cost. To this end, when cutting a metal plate 1101 by irradiation of a laser beam, a laser beam 1011 emitted in the form of pulses and having a circular section is converted by a beam section transformer 1020 into a laser beam 1012 having an elongate elliptic section. The section of the laser beam 1012 is rotated on its optical axis by a beam rotating device 1030 so that the lengthwise direction of the section of the laser beam 1012 is coincident with the lengthwise direction of each of inner leads 1013. An optical axis of a laser beam 1015 is revolved along each of concentric paths 161 to 174 around the original optical axis given when the laser beam 1011 is emitted.

Abstract: A metal surface is now described having enhanced adhesion of subsequently applied coatings. The substrate metal of the article, such as a valve metal as represented by titanium, is provided with a highly desirable surface characteristic for subsequent coating application. This can be initiated by selection of a metal of desirable metallurgy and heat history, including prior heat treatment to provide surface grain boundaries which may be most readily etched. In subsequent etching operation, the surface is made to exhibit well defined, three dimensional grains with deep grain boundaries. Subsequently applied coatings, by penetrating into the etched intergranular valleys, are desirably locked onto the metal substrate surface and provide enhanced lifetime even in rugged commercial environments.

Abstract: A dry sandblasting treatment for spraying abrasives onto a surface of an insulating resin layer, a chemical etching for chemically etching the surface, and a plating process for plating a conductive layer on the resulting insulating resin layer are successively performed. Since the surface of the insulating resin layer is roughened by the dry sandblasting treatment and the resulting surface is subjected to the chemical etching, a minute anchor structure is formed on the surface. Accordingly, the adhesion between the insulating resin layer and a plating layer (i.e., a circuit conductive layer) is improved. Due to the dry sandblasting treatment, the shape of a via hole formed in the insulating resin layer is improved, and an exposed surface of the circuit conductor layer and an inner wall of a through-hole are cleaned.

Abstract: A method and non-fiber-forming, molded article-forming structure for making a non-fiber, multicomponent molded article containing a plurality of components in a predetermined spatial, non-laminate configuration, wherein the method involves feeding the plurality of respectively dissimilar fluid components, mutually separated, into the molded article-forming structure, which contains a plate flow distributor and a non-fiber-forming shaping section; wherein the flow distributor is made up of at least one distribution plate which is preferably thin and has micromachined on at least one facial surface thereof multiple distribution flow paths having a flow pattern effective to distribute and combine the plurality of components in the predetermined spatial, non-laminate configuration; directing the mutually separated components through the multiple distribution flow paths to distribute and arrange the components to form a fluid structure containing the plurality of components in the predetermined spatial, non-lamina

Abstract: A design and manufacturing process uses flat sheets with outline shapes cut into the metal to manufacture orthodontic parts in laminate form. These sheets are aligned and stacked together, tack welded and brazed together in a flat form or may be bent together and then brazed. The process may be used to produce either commonly used conventional orthodontic brackets or very complicated shapes required for difficult applications.

Abstract: The invention provides mainly a selective etching method for the total or partial chemical ablation at certain positions of a metal sheet, and a waveguide obtained by said method. Complete ablation is obtained by etching both faces of the metal sheet. Partial ablation is obtained by etching only one of the faces of the metal sheet. Partial ablation allows grooves and semi-thicknesses to be obtained for forming bends and rabbets for the formation of three dimensional pieces.

Abstract: A valve assembly for controlling fluid flow includes a valve plate and a nozzle plate which are not attached to each other but can be moved into and out of contact with each other. The valve plate has an opening for passing an actuator and fluid. A nozzle plate has an opening for passing fluid and the opening is aligned with a mesa on the valve plate which can seal the nozzle orifice. The actuator separates the nozzle plate from the valve plate to permit fluid flow and a spring means brings the nozzle plate into a closed position against the valve plate to stop fluid flow.

Abstract: An apparatus and method for forming an integral three-dimensional object from laminations of the same or gradually varying shape. The apparatus includes a supply station, a work station for forming a material into a plurality of laminations for the three-dimensional object, a control station for directing the operation of the work station, an assembling station for stacking the laminations in sequence into the three-dimensional object, and bonding the laminations to complete the formation of the three-dimensional object.

Abstract: A method of producing a plate-shaped bearing member for sliding bearings, the structure being composed of a patterned body of supporting bearing material and a lubricant, utilizing a galvanoplastic fabrication step, the method including: producing a mold provided with a pattern of recesses, the step of producing including performing an X-ray deep-etch lithography procedure; filling the recesses to form the body of bearing material; removing the mold from the body of bearing material so that spaces are left in the bearing material; and filling the thus produced spaces with the lubricant.

Abstract: A diamond-coated tungsten carbide-base sintered hard alloy material for inserts of cutting tools, which has greatly improved bond strength or degree of bonding of the diamond coating layer to the matrix and therefore is capable of exhibiting excellent cutting performance over a long period of time.The sintered hard alloy material comprises:(1) a matrix of a sintered hard alloy consisting essentially of 1-4 percent by weight cobalt, and the balance of tungsten carbide and inevitable impurities, the tungsten carbide having a coarse grain structure having an average grain size of 2-10 microns; and(2) a diamond coating layer formed over surfaces of the matrix by forming an etching layer over the matrix surfaces and then forming the diamond coating layer over the matrix surfaces via the etching layer by a low pressure vapor-phase synthesization method.If required, the matrix may further contain CO1-CO8 (ISO) free carbon.

Abstract: A method for producing a metallic substrate used for an automobile exhaust gas purifying device, which comprises the steps of: preparing a heat-resisting steel member having a length and capable of containing therein other members; densely filling the heat-resisting steel member with easy-soluble material members and with stainless steel members for separating the easy-soluble material members from each other, to form a filled body; hot-working the filled body to reduce the cross sectional area thereof for achieving a metallic bond between the stainless steel members; cutting the filled body to a predetermined length; and removing the easy-soluble material from the filled body by a chemical and/or an electrochemical treatment for boring throughholes to expose catalyst carrier-destined surfaces of the stainless steel.

Abstract: A single-piece thermally isolated multi-point injector for a hydrazine fuel catalytic gas generator having a series of integral feed tubes each with a fuel passage and with the fuel inlet ends thereof spaced apart for ease of manufacture and inspection and associated with a distribution manifold. The feed tubes are arranged in spaced-apart circular arrays to facilitate formation thereof from an investment casting or by radial electrochemical machining cuts. The fuel injector retains the thermal isolation features of a welded or brazed capillary tube injector, but eliminates leakage points encountered in such a structure. The outlet end of each feed tube has a porous member associated therewith to obtain a uniform flow path of hydrazine fuel in all directions onto a catalyst bed.

Abstract: The present invention relates to a method for producing spinning nozzle plates having funnel-shaped preliminary channels in flow communication with nozzle capillaries. Two embodiments of the method are provided which use photolithographic and electrodeposition techniques. Common to both embodiments of the method is the use of a metal plate provided with funnel-shaped preliminary channels as a self-aligning irradiation mask for irradiating a photoresist layer provided on the metal plate. Nozzle capillaries subsequently defined either in an electrodeposited layer according to a first embodiment of the invention or in electrodeposited tubular projections according to a second embodiment of the invention, have an offset-free, continuous transition between themselves and the preliminary channels. Photolithographic and electrodeposition techniques may also be used to define the funnel-shaped preliminary channels in the metal plates.

Abstract: A silicon valve for controlling the flow of a fluid includes two generally planar silicon members. One has an orifice for passing the fluid and the other has a relatively moveable surface to selectively open and close the orifice thereby controlling the flow of fluid through the orifice. A method is disclosed which method addresses the fabrication of the aforementioned silicon valve, wherein an oxide is grown on the surface of a wafer and the wafer then is etched to define a valve seat pattern. Both a top and a bottom plate are fabricated from wafer material and the profiled wafers are bonded together in a manner which will allow fluid passage therethrough.

Abstract: Methods for manufacturing components having internal flow passages in which an insert composed of a carrier and passage-forming and/or flow controlling elements is sandwiched between or installed in elements of the component. The insert associated and component elements are then bonded together and the carrier subsequently leached away to complete the formation of the flow passages.

Abstract: A hollow composite airfoil with an integral internal support rib of fluoroelastomer rubber is formed by bracketing the rib between two silicone rubber mandrels to form a core assembly having a desired aerodynamic shape, then building up on opposite sides of the core assembly separate stacks of laminae of a composite material of graphite (or carbon) and glass fibers impregnated with an epoxy resin, with the two stacks overlapping adjacent to the leading and trailing edges of the core assembly. Heat and pressure are then applied to the core assembly with the laminae thereon to bond together the laminae of each stack, then to bond the two stacks together along the overlapping portions thereof and to bond the two stacks to the rib to form a continuous shell around the core assembly. The mandrels are then removed. One open end of the resulting hollow airfoil is plugged and that end is inserted into a recess in a mounting platform with a predetermined clearance space therebetween.

Abstract: A method for forming small-orifices 20 in the face plate 10 of an injector 12, especially a liquid propellant injector for a rocket engine. A stainless steel base plate is given a first layer 28 of electrodeposited Ni and fuel feed passages 24 and 26, respectively, are formed therethrough for fuel and oxidizer transfer. The feed passages 24 and 36 are filled with wax and silver is worked into the surface of the wax to permit electrodeposition of face plate 10. Connecting bores 42 to the perforations are made through the face plate nickel layer 40. Plastic mandrels 44 are fabricated, having legs 46 with support sections 48 and orifice-forming sections 50 and coupling tabs 54 for tying the legs 46 together. The support legs 48 of the mandrels 44 are inserted in the connecting bores for support and another layer 60 of Ni is electrodeposited to enclose the orifice-forming sections 50 of the mandrel legs 46.

Abstract: An improved method of making an airfoil includes stacking plies in two groups. A separator ply is positioned between the two groups of plies. The groups of plies and the separator ply are interconnected to form an airfoil blank. The airfoil blank is shaped, by forging or other methods, to have a desired configuration. The material of the separator ply is then dissolved or otherwise removed from between the two sections of the airfoil blank to provide access to the interior of the airfoil blank. Material is removed from inner sides of the two separated sections to form core receiving cavities. After cores have been placed in the cavities, the two sections of the airfoil blank are interconnected and the shaping of the airfoil is completed. The cores are subsequently removed from the completed airfoil.

Abstract: A method for forming small-diameter, angled ducts and manifolds in a face plate for a rocket-engine injector or the like. A surface of a circular base plate 16 is formed with an annular flange 18 thereon having two inwardly sloping sides 11 and 13. Grooves 20, 22 are machined along the intersections of the sides 11 and 13 with the surface of the base plate 16 for propellant-containing manifolds 36 and 38. Grooves 10 are etched in spaced sets of two down the sloping sides of the flange from the flange top 24 to the manifold grooves 20,22. The grooves 10, 20, 22 are filled with wax 23 and a layer 26 of metal is electrodeposited over the grooved surface of the base plate 16 to cover the top 24 of the flange 18, the deposited layer forming orifice ducts and propellant manifolds from the grooves. This layer 26 is machined down to a depth at which the orifice ducts 34 are exposed so that orifices 12 appear at the surface 30 of the machined layer. The wax 23 is now removed by heat or a solvent.

Abstract: Systems and methods for detecting and eliminating short circuit current paths through photovoltaic devices of the type including at least one semiconductor region overlying a substrate and a layer of conductive light transmissive material overlying the at least one semiconductor region are disclosed. The short circuit current paths which are eliminated extend through the at least one semiconductor region from the substrate to the layer of conductive light transmissive material. The resistivity of the short circuit current path is increased substantially at the interface between the conductive light transmissive material and the semiconductor region by isolating electrically the conductive light transmissive material from the short circuit current path.The isolation can be provided by removing the transparent conductive material from electrical contact or connection with the short circuit current path.

Abstract: In the disclosed method for fabricating corrugated microwave components, a billet assembly is formed of electrically conductive plates sandwiched with chemical etching sensitive spacer material and clamped together. An inside surface is formed in the billet and a mandrel inserted. An outer contoured surface is then formed on the mandrel-billet assembly. The outer surface is then plated to a desired thickness. The mandrel is removed and the spacers chemically etched away leaving the finished component. With the disclosed method, microwave device fabrication for frequencies including 100 GHz and higher is possible.

Abstract: A fluid resistor with a fluid tight structure including two planar members having a surface of each contacting in close proximity. One of the planar members has a laminated structure including a substrate and at least one thin layer of substantially uniform thickness formed on the substrate. A groove extends through the layer. The groove and the surface of the other planar member define a capilliary passageway of substantially constant depth for restricted fluid flow.

Abstract: A method of making an annular biased frequency interference shielding member having securement tabs for mounting between plug and receptacle shells of an electrical connector, and having folded resilient fingers having base and distal portions respectively engageable with said plug and receptacle shells under resilient pressure engagement. The folded resilient fingers are precisely dimensioned and formed about an axis such that minimal space intervals are provided between adjacent edges of adjacent resilient fingers whereby virtually 360.degree. shielding integrity is afforded.

Abstract: The invention contemplates improved techniques for making lens implants for use in ophthalmological surgery, the lens being a replacement for a cataract-clouded natural lens, and the replacement being installed in the pupil at the iris as the operative step following removal of the cataracted lens. The lens produced by the inventive method features adapter structure assembled to an intra-ocular lens element and having first and second pluralities of radially outward stabilizing feet, in angularly spaced and interlaced relation with the feet of the other plurality; and the respective pluralities of stabilizing feet are on opposite sides of the iris, thus enabling the iris to retain and position the implanted lens.

Abstract: A rotary electrical switch is provided of the type that includes a stator body of substantially cylindrical shape having a cylindrical opening coaxially disposed therein. The stator body includes a plurality of electrical contacts embedded in the stator body at circumferentially spaced positions therearound and extending radially inward from the cylindrical opening in the stator body and having a pair of parallel disposed planar contact surfaces, all of the contacts being disposed in a common plane orthogonal to the longitudinal axis of the cylindrical opening. A rotor body is rotatably disposed in the cylindrical opening and a contactor clip including a pair of contactors electrically and resiliently engaging both planar contact surfaces of respective ones of the contacts is constrained to rotate with the rotor body.

Abstract: A silver color coin or medal is produced from a copper-silver alloy containing from about 30 to 60% by weight of silver. The normal rose color caused by the copper in the alloy is removed by selective electrolytic etching.

Abstract: A plurality of individual pre-shaped cores or pins are initially positioned in a prearranged orientation upon an outlet surface of a die body by means of a plate of photosensitive glass or glass-ceramic material which has been etched to form a mask with the desired pattern or arrangement of openings for orienting said cores or pins upon said die surface for subsequent securement thereto such as by welding.

Abstract: An electrode set for use in a recording apparatus and comprising a row of substantially wire-shaped electrode pins projecting freely coplanar and parallel to each other from a common carrier and being provided with integral connecting terminals for the supply of selective actuation signals, is manufactured by etching a number of plate-shaped blanks of the electrode material, so that each of them produces a number of electrode pins, the spacings between which are at least equal to the thickness of the blank after which the blanks are bent in different direction along bending lines at right angles to the electrode pins and are coupled together under mutual parallel displacement by means of a special tool, so that each spacing between adjacent electrode pins in one blank will accommodate in the same plane one electrode pin from each of the remaining blanks, the resulting spacing between the electrode pins being essentially smaller than the thickness of the electrode pins.

Abstract: A process for forming stepped lids for microelectronic circuit cases. A plurality of interconnected lids is etched in a metal sheet with the lids oversize. Individual lids are stamped from the sheet to the desired size, providing substantially square corners at the edge of the lid and a substantially flat rim for engagement with the case.