How It's Made (2001–…): Season 5, Episode 7 - Golf Balls/Furniture Handles/Parking Meters/Room Dividers - full transcript
CAPTIONS PAID FOR BY
DISCOVERY COMMUNICATIONS, INC.
Narrator:
TODAY ON "HOW IT'S MADE"...
GOLF BALLS.
FURNITURE HANDLES.
PARKING METERS.
AND ROOM DIVIDERS.
DIFFERENT TYPES OF GOLF BALLS
DELIVER DIFFERENT RESULTS.
HIGHLY SKILLED GOLFERS OFTEN USE
WHAT'S CALLED A WOUND BALL --
A BALL MADE OF RUBBER THREAD
WOUND TIGHTLY OVER A CORE --
BECAUSE ITS FLIGHT
IS MORE CONTROLLABLE.
BUT MOST PEOPLE USE WHAT'S
CALLED A TWO-PIECE BALL --
A BALL WHOSE CORE IS COVERED
IN A DIMPLED MATERIAL.
TODAY'S GOLF BALL
HAS REALLY COME A LONG WAY
IF YOU CONSIDER THAT THE EARLY
ONES WERE MADE OF FEATHERS.
THIS IS WHAT'S INSIDE NOW --
A BOUNCY RUBBER.
THEY MIX IT UP WITH OTHER
CHEMICALS TO MAKE A HOT BATTER
AND THEN ROLL IT OUT
LIKE A PIE CRUST,
COOLING IT
BETWEEN TWO HUGE STEEL DRUMS.
NEXT THEY PUSH
THE ROLLED-UP RUBBERY SHEETS
INTO THIS MACHINE,
CALLED AN EXTRUDER.
THERE'S A RAM INSIDE, AND IT
FORCES THE RUBBER THROUGH A DIE.
THIS MAKES SHAPES THAT RESEMBLE
LARGE MARSHMALLOWS,
CALLED SLUGS.
A CONVEYOR BELT SENDS THEM
TO A COMPRESSION-MOLD MACHINE.
HERE A WORKER POSITIONS
THE SLUGS IN A STEEL MOLD.
THE SLUGS OFTEN VARY IN COLOR
DEPENDING ON THE TYPE OF BALL
BEING PRODUCED.
WHEN THE DOOR CLOSES,
THE BOTTOM PART OF THE MOLD
PRESSES UP INTO THE TOP PART,
APPLYING OVER A TON OF PRESSURE.
THIS IS A SHAPE-AND-BAKE SYSTEM
BECAUSE INSIDE THIS MOLD,
THE NEWLY ROUNDED RUBBER
IS COOKING
AT 332 DEGREES FAHRENHEIT.
BAKING IT FOR 13 MINUTES
HARDENS IT.
THEN AFTER IT'S COOLED
WITH WATER,
A WORKER PLACES A PIECE OF
SLOTTED PLEXIGLAS OVER THE MOLD.
THIS HOLDS DOWN
THE LEFTOVER TRIMMINGS
SO THAT ONLY THE BALL SHAPES
GET PICKED UP BY THE VACUUM.
HE PEELS OFF THE EXCESS RUBBER
FOR RECYCLING LATER.
THE MARSHMALLOW-SHAPED SLUGS
HAVE NOW BEEN TRANSFORMED
INTO A SOLID GOLF-BALL CORE.
A ROBOT TRANSPORTS THESE CORES
TO ANOTHER MOLD.
A RAM PUSHES MELTED PLASTIC
THROUGH TUBES
AND INTO A MOLD CAVITY.
THIS FORMS THE OUTSIDE SHELL
OF THE GOLF BALL,
COMPLETE WITH THE DIMPLES
THAT WILL HELP THE BALL
TRAVEL FARTHER.
THIS IS AN INSIDE LOOK AT A BALL
WITH ITS NEW SHELL.
THIS INJECTING-MOLDING SYSTEM
GENERATES FOUR DOZEN GOLF BALLS
EVERY MINUTE.
THE NEW BALLS ARE ON THE MOVE.
THEY ROLL INTO A BIN
WHICH FUNNELS THEM
TO A GOLF-BALL ELEVATOR.
THEY'RE ON THEIR WAY
TO GET CLEANED UP.
LOOK CLOSELY, AND YOU'LL SEE
LITTLE PIECES OF LEFTOVER
PLASTIC ON THE BALL SHELLS.
THE NEXT PROCESS
WILL GET RID OF THAT.
THIS IS AN AUTOMATIC MILLER
THAT REMOVES THE EXCESS PLASTIC.
THIS IS A GOLF BALL
BEFORE MILLING.
AND HERE IT IS AFTER.
THE FLECKS OF PLASTIC
HAVE BEEN REMOVED.
NEXT ROBOTIC ARMS
SHOVEL THE GOLF BALLS
TOWARDS A CHUTE ENTRY.
THIS IS A QUALITY CHECKPOINT.
IF THE BALL IS NOT SMOOTH
AND UNIFORM,
IT WON'T GO THROUGH THIS HOLE.
NOW A WHEEL ROLLS THE GOLF BALLS
TOWARDS A STAMPING MACHINE.
ROBOTIC ARMS CARRY SILICONE PADS
TO AN ETCHED STEEL PLATE.
THE PADS SOAK UP INK
FROM THE ETCHED PLATE
AND TRANSFER IT TO THE BALLS.
THE PADS BRAND EACH BALL
WITH A PLAYER NUMBER,
THE COMPANY NAME,
AND THE MODEL TYPE.
THEN BEAMS OF ULTRAVIOLET LIGHT
HARDEN THE INK.
THEY DUMP THE BALLS INTO A BIN,
BUT THEY FUNNEL SOME BALLS OVER
TO ANOTHER STAMPING MACHINE.
THIS ONE DOES CUSTOM LOGOING.
NOW, THAT'S A STAMP OF APPROVAL.
NEXT AN AUTOMATED MACHINE SPRAYS
THE BALLS WITH POLYURETHANE
WHILE THEY ROTATE ATOP SPINDLES.
THE POLYURETHANE
PROTECTS THE INK LOGOS
THAT HAVE BEEN STAMPED
ON THE BALLS.
ROBOTIC ARMS CARRY THE WET
GOLF BALLS TO A DRYING RACK,
WHERE THEY COOK AT 150 DEGREES
FAHRENHEIT FOR 5 MINUTES.
THEN THEY'RE DONE.
AND THAT'S THE TECHNIQUE
BEHIND THE GOLF BALL.
IT'S UP TO YOU TO EXPLAIN
YOUR GOLF TECHNIQUE.
Narrator: IMAGINE A DRESSER
WITH ANTIQUE-STYLE BRASS PULLS.
NOW IMAGINE THAT SAME DRESSER
WITH COUNTRY-STYLE WOODEN KNOBS
OR FUNKY PLASTIC KNOBS OR SLEEK
HANDLES IN STAINLESS STEEL.
THE DECORATIVE HARDWARE
ON A PIECE OF FURNITURE
OR ON CABINETRY
DRAMATICALLY AFFECTS ITS LOOK,
SO CHANGING THEM IS AN EASY
AND INEXPENSIVE MAKEOVER.
HOW WOULD WE GET A GRIP
ON THINGS
WITHOUT KNOBS AND HANDLES?
THEY'RE MORE THAN SOMETHING
THAT CAN OPEN DOORS FOR YOU.
THE MANY STYLES ADD
TO THE APPEAL OF OUR FURNITURE.
TO MAKE A HANDLE, AN ELECTRICAL
HOIST DROPS BIG CHUNKS OF ZINC
INTO A MELTING FURNACE.
AT 800 DEGREES FAHRENHEIT,
METAL QUICKLY TURNS INTO LIQUID.
IT'S SO HOT, YOU'D LOSE A FINGER
IF YOU TOUCHED IT.
AUTOMATED ARMS MOVE AN IRON POT
FULL OF THE LIQUID
TO A RAILROAD CAR,
WHICH TAKES IT
TO THE NEXT STAGE.
HERE THEY POUR THE LIQUID METAL
INTO ANOTHER FURNACE
THAT'S JUST AS HOT.
THIS IS CALLED
A MACHINE FURNACE.
A HYDRAULICALLY DRIVEN CYLINDER
PUSHES THE LIQUID METAL
THROUGH A SYSTEM OF NOZZLES
AND PIPES
THAT RUN THROUGH THE FURNACE.
IT CARRIES THE LIQUID METAL
TO A DIE.
THE DIE SHAPES THE HANDLES
COOKIE-CUTTER STYLE.
WATER FLUSHES THROUGH THE DIE.
THIS COOLS DOWN THE ZINC,
AND IT HARDENS
INTO A HANDLE SHAPE
WITH A LOT OF EXTRA MOLDING
THAT THEY'RE GOING TO HAVE
TO GET RID OF.
SO, NOW THAT THEY'VE COOLED,
IT'S SAFE TO TOUCH THEM
AND REMOVE SOME OF THAT WASTE.
A WORKER SNAPS SOME OF IT OFF
AND TOSSES IT INTO A BIN
FOR RECYCLING LATER,
AND THE HANDLE SHAPES
GO INTO A SEPARATE BIN.
BUT THERE ARE STILL SOME LITTLE
BITS OF WASTE ON THE HANDLES
CALLED OVERFLOWS,
SO A MECHANICALLY DRIVEN SPINNER
TOSSES THE HANDLES AROUND
AND KNOCKS OFF ANY OVERFLOWS
THAT HAVE BEEN MISSED.
IT'S A LOT FASTER THAN PICKING
OFF THOSE LITTLE PIECES BY HAND.
A WORKER DUMPS THE HANDLE SHAPES
INTO A BIN.
THEY'RE DEFINITELY STARTING
TO TAKE SHAPE NOW.
A SIMILAR DIE-CASTING SYSTEM
IS USED TO MAKE KNOBS,
BUT THE KNOBS COME
IN TWO INTERLOCKING PIECES.
THEY PLACE THEM ON A TURNTABLE
AND FIT THEM TOGETHER.
THEN A 4-TON HYDRAULIC PRESS
PRESSES DOWN ON THE KNOB,
AND THAT PRESSURE SEALS THEM.
THEY POUR A MIXTURE
OF WATER AND OIL ON THE KNOBS
TO COOL AND LUBRICATE THEM,
WHILE AN AUTOMATED MACHINE
DRIVES A SCREW INTO THE BACK
OF THE KNOB.
THIS MAKES A THREAD PATTERN
INSIDE OF IT
SO IT CAN BE EASILY SCREWED
ONTO FURNITURE LATER.
NOW THEY PLUNGE THE HANDLES
INTO A CHEMICAL BATH.
THE CHEMICALS HELP
TO CONDUCT ELECTRICITY.
THIS PROCESS
IS CALLED ELECTROPLATING.
THE HANDLES
ARE NEGATIVELY CHARGED.
THE BRASS PARTICLES IN THE WATER
ARE POSITIVELY CHARGED.
THEY ATTRACT AND CONNECT,
AND THIS CAUSES
THE BRASS PLATING TO FORM.
THEY DIP THE HANDLES
INTO THE CHEMICAL WASH TWICE
AND THEN RINSE TWICE.
NEXT THEY DUMP THE BRASS HANDLES
INTO A VAT OF ACID.
THIS OXIDIZES IT,
BLACKENING THE FINISH
TO MAKE IT LOOK ANTIQUE.
THIS BRASS PULL HAS AGED
A HUNDRED YEARS
IN JUST A FEW MINUTES.
NEXT THEY FUNNEL THE HANDLES
INTO A BIG, ROUND POLISHER.
IT'S CALLED A BOWL VIBRATOR.
THE HANDLES ARE MIXED IN
WITH STEEL BALL BEARINGS.
THE MACHINE VIBRATES,
AND THE FRICTION FROM THE BALL
BEARINGS POLISHES THE HANDLES.
NOW THOSE ANTIQUE BRASS HANDLES
HAVE A SHINIER FINISH.
SOMETIMES THEY USE
CERAMIC PELLETS IN THE POLISHER
INSTEAD OF BALL BEARINGS.
THEY SPRAY SOAP AND WATER
INTO THE BOWL
TO LUBRICATE THE HANDLES
AND ALLOW THEM TO MOVE FREELY.
THIS GENTLER FRICTION
RESULTS IN A DIFFERENT FINISH.
THE POLISH ON THE HANDLES
WILL BE BRIGHTER.
NOW THEY PUT A HANDLE
INTO A CLAMP.
WITH AIR PRESSURE,
IT SQUEEZE THE HANDLE
SO THAT IT HOOKS
INTO A BACKPLATE.
WHEN THE PRESSURE IS RELEASED,
THE FIT IS SNUG.
A FRONT AND BACKPLATE GIVES
A HANDLE A MORE ELABORATE LOOK.
THEY BUFF UP A KNOB
WITH A CLOTH POLISHING WHEEL
THAT'S MECHANICALLY DRIVEN.
THIS PROCESS GIVES KNOBS
AND HANDLES A CERTAIN GLEAM.
IT'S THE FINISHING TOUCH.
Narrator:
THE BEATLES WROTE A SONG ABOUT
LOVELY RITA THE METER MAID,
BUT TRY FINDING ANYONE ELSE
SINGING THE PRAISES
OF THOSE UNIFORMED PATROLS
WHO TICKET YOUR CAR
WHEN YOUR METER EXPIRES.
PARKING METERS HAVE BEEN AROUND
SINCE THE 1930s,
AND EVER SINCE THEN, DRIVERS
HAVE HAD TO PAY FOR PARKING.
IT'S TIME TO FIND OUT
JUST HOW THESE HEAVY-DUTY
PIGGY BANKS ARE MADE.
FIRST THE LOW-TECH PART.
THE TIME-LIMIT LABEL GOES
ONTO A ZINC DOME-SHAPED PLATE.
THEN A WORKER SPRAYS LUBRICANT
ONTO VARIOUS PARTS
OF THE MOTHERBOARD
THAT CONTAINS
COMPUTER CIRCUITRY.
AFTER HE SNAPS THE BOARD
ONTO THE PLATE, HE SCREWS IT IN.
THEN HE FASTENS ANOTHER
DOME-SHAPED PLATE ONTO THE BACK,
SANDWICHING THE MOTHERBOARD
BETWEEN THE TWO PLATES.
THE WORKER HOOKS THE BOARD UP
TO THE POWER SOURCE --
THE BATTERY PACK --
AND HE TUCKS THE PACK
INTO A SPECIAL COMPARTMENT
SO THAT IT'S SECURE.
THEN HE PLUGS A PROGRAMMING
DEVICE CALLED AN "X" KEY
INTO PRONGS PROTRUDING
FROM THE MOTHERBOARD.
THE KEY FEEDS SOFTWARE
TO THE MOTHERBOARD INSIDE.
WHEN NUMBERS APPEAR
ON THE SCREEN, IT'S PROGRAMMED.
THE NEXT PIECE,
CALLED A SmartChute,
ALSO HAS COMPUTER CIRCUITRY.
IT ANALYZES THE COINS
AS THEY FALL THROUGH THE METER.
IT CAN EVEN RECOGNIZE COINS
FROM OTHER COUNTRIES.
HE PUTS THE CHUTE INTO
A PROTECTIVE PLASTIC CASING
AND PLUGS IT
INTO THE PROTRUDING PRONGS
THAT WERE USED EARLIER
TO PROGRAM THE METER.
THE TWO BOARDS
MAKE A CONNECTION
AND CAN NOW COMMUNICATE
TO ONE ANOTHER.
HE CLICKS ANOTHER ZINC PLATE
OVER THE COIN CHUTE
AND ADDS A STAINLESS-STEEL
COIN SLOT FOR ADDED PROTECTION.
THIS CARD
IS A RADIO-FREQUENCY PROBE
THAT DETECTS HOW MUCH MONEY
IS IN THE METER
AS WELL AS
MAINTENANCE INFORMATION.
JUST HOW GOOD IS A PARKING METER
AT ANALYZING COINS?
THIS PARTICULAR METER
WAS MADE IN CANADA.
A CANADIAN NICKEL
AND A BRITISH 20 PENCE
ARE ROUGHLY THE SAME SIZE.
PUT IN A CANADIAN NICKEL,
AND YOU GET THREE MINUTES.
BUT TRY THE 20 PENCE.
NOTHING REGISTERS.
THE METER TREATS IT
LIKE A PLUG NICKEL.
THE METERS ARE NOW
IN AN ENVIRONMENTAL CHAMBER.
THIS CHAMBER REPLICATES THE MOST
EXTREME CLIMATE CONDITIONS.
IT'S A TEST TO MAKE SURE THEY'RE
READY FOR LIFE ON THE STREET.
NOW IT'S TIME TO MAKE A LOCK.
HE PUTS A ZINC-ALLOY LOCK PLUG
CONTAINING BRASS TUMBLERS
INTO A MINIATURE LATHE.
THE LATHE SPINS RAPIDLY
ON ITS AXIS
WHILE PRESSING
AGAINST THE HARD STEEL BLADES.
THE BLADES CUT
THE SPINNING LOCK TUMBLERS
TO THE APPROPRIATE LENGTH.
THE RESULT?
A LOCK PLUG THAT HAS BRASS
TUMBLERS OF DIFFERENT LENGTHS
THAT CAN'T BE OPENED
WITHOUT THE CORRECT KEY.
HERE A WORKER PLACES
THE LOCK BARREL IN A VISE
TO GIVE A BETTER VIEW
OF THE LOCK SYSTEM.
AS YOU CAN SEE,
IT TURNS EASILY WITH THE KEY.
BUT, VANDALS, BEWARE.
THIS LOCK IS DESIGNED
TO BE TOUGH TO PICK.
NEXT HE INSERTS THE LOCK
INTO THE BOTTOM OF A COIN CAN
THAT'S MADE OF PLASTIC.
HE CLOSES IT
AND THEN PUTS IT ON WHAT'S
CALLED A SONIC WELDING MACHINE.
IT EMITS HIGH-FREQUENCY
SOUND VIBRATIONS
THAT ACTUALLY MELT
THE RIGID PLASTIC,
WELDING THE TOP
AND BOTTOM PIECES TOGETHER.
NOW THESE COINS WILL BE
REALLY TOUGH TO GET OUT
WITHOUT THAT KEY.
NEXT HE BRUSHES A SECOND LOCK
SYSTEM WITH A LUBRICANT
AND ADDS A HARD STEEL SHIELD
THAT WILL RESIST ATTEMPTS
TO DRILL INTO IT.
THIS LOCK GOES ONTO AN IRON DOOR
WHICH WILL BE PART OF THE VAULT
THAT CONTAINS THE COIN CAN.
HE BRUSHES THE LOCK ASSEMBLY
WITH ANOTHER LUBRICANT
TO MAKE THE LOCKING OPERATION
SMOOTHER.
THEN HE INSTALLS A RUBBER GASKET
ALONG THE FRAME
FOR THE METER DOME WINDOW.
THIS GASKET SEALS THE DOME
AND PROTECTS THE ELECTRONICS
FROM HARSH WEATHER.
HE PLACES A TOUGH PLASTIC WINDOW
ON THE GASKET
AND TOPS IT WITH A ZINC STRAP.
HE SCREWS ALL THE PIECES
TOGETHER.
THEN HE PLACES THE IRON CASE
THAT WILL HOLD ALL THE MECHANICS
ON TOP OF THE VAULT
CONTAINING THE COIN CAN.
HE ATTACHES THE WINDOWED CAP
AND STRAP ASSEMBLY WITH HINGES.
AND THERE'S A THIRD LOCK
TO HELP PROTECT THE ELECTRICAL
COMPONENTS OF THE PARKING METER.
AFTER A CHECK
FOR FIT AND FUNCTION,
HE INSTALLS
THE ACTUAL MECHANICS.
THIS MEANS IT'S ALL SYSTEMS GO.
THE PARKING METER IS READY
FOR THE STREET.
LATER THE COINS CAN BE COLLECTED
WITHOUT EVEN OPENING
THE PLASTIC COIN CAN.
THIS SPECIAL RECEPTACLE
ACTIVATES THE LOCK
AT THE BOTTOM OF THE CAN.
ONCE TURNED, THE COINS DEPOSITED
INTO THE PARKING METER
DROP INTO THE RECEPTACLE.
Narrator: IF YOU NEED
TO SECTION OFF PART OF A ROOM,
THERE ARE MANY TYPES OF ROOM
DIVIDERS THAT CAN DO THE JOB.
ACCORDION DOORS ROUTINELY DIVIDE
MEETING ROOMS.
SLIDING WALLS MADE UP
OF MULTIPLE PANELS
CAN EASILY SPLIT
A LARGE RECEPTION HALL IN HALF
OR PARTITION AN OFFICE
IN NO TIME AT ALL.
THIS PARTICULAR COMPANY MAKES
TWO TYPES OF ROOM DIVIDERS --
SLIDING PANELS
CALLED OPERABLE WALLS
AND ACCORDION DOORS.
BOTH HAVE
BUILT-IN SOUNDPROOFING.
THE FOLDING MECHANISM
AT THE CORE OF AN ACCORDION DOOR
IS CALLED A PANTOGRAPH.
IT'S MADE OF FLAT STEEL BARS
RIVETED TOGETHER
IN A CRISSCROSS CONFIGURATION.
A WORKER TIGHTENS THE RIVETS
JUST ENOUGH TO HOLD THE BARS
IN POSITION
WITHOUT IMPEDING THEIR MOVEMENT.
THEN HE INSERTS PINS
ALONG THE TOP AND BOTTOM,
SECURING THEM
WITH STEEL RETAINING RINGS.
THE PANTOGRAPH IS CUSTOM-BUILT
TO EXPAND TO THE PRECISE WIDTH
OF THE DOOR THEY'RE MAKING,
THE PINS ATTACHED TO THE COVERS
THAT WILL LATER
SANDWICH THE PANTOGRAPH,
FORMING THE ACCORDION DOOR'S
SURFACE.
TO MAKE THOSE COVERS,
THEY FIRST MAKE SLATS.
THIS AUTOMATED MACHINE
HOT-GLUES A BAND OF CARDBOARD
ONTO A BAND OF STEEL.
THEN A SERIES OF ROLLERS
PROGRESSIVELY FOLDS
THE SIDES UPWARD,
FORMING A STEEL EDGE
AROUND THE CARDBOARD.
FINALLY THE MACHINE CUTS
THE CONTINUOUS BAND INTO SLATS,
WHOSE LENGTH IS THE HEIGHT
OF THE ACCORDION DOOR
THEY'RE MAKING.
NOW WORKERS PAIR UP THE SLATS,
CONNECTING THEM
WITH CARDBOARD STRIPS.
THEY FEED EACH PAIR
INTO A GLUE MACHINE.
THE SLATS COME OUT ADHERED
TO A SOFT AND FLEXIBLE TYPE
OF PAPER THAT'S TEARPROOF.
NEXT WORKERS CONNECT SIX PAIRS
OF SLATS TO FORM A PANEL.
THEN THEY GLUE ON
THE DECORATIVE SURFACE --
IN THIS CASE,
COMMERCIAL-QUALITY VINYL.
TO BLOCK SOUND FROM PASSING
THROUGH THE SPACE
ABOVE AND BELOW
THE ACCORDION DOOR,
A WORKER GLUES
A FELT-AND-VINYL STRIP
TO THE TOP AND BOTTOM
OF EACH PANEL.
AFTER LINING THE INSIDE OF EACH
PANEL WITH ACOUSTIC WOOL,
A SOUNDPROOFING MATERIAL,
ANOTHER WORKER GATHERS
THE NUMBER OF PANELS
REQUIRED FOR THE DOOR'S WIDTH.
HE ATTACHES THEM
USING INDUSTRIAL-STRENGTH
STEEL STAPLES.
THEN HE SLIPS
U-SHAPED STEEL CHANNELS
ONTO WHAT WILL BE
THE DOOR'S INSIDE FOLDS.
USING AN AIR-POWERED MACHINE
CALLED A SERTER,
HE PRESSES THE CHANNELS TIGHTLY
IN PLACE.
NOW HE INSTALLS THE PENTOGRAPHS.
THE HEIGHT OF THE DOORS
DETERMINE HOW MANY.
USING STEEL RETAINING RINGS,
HE LOCKS THE PENTOGRAPH PINS
INTO HOLES ON THE CHANNELS.
THE SECOND COVER GOES ON
THE SAME WAY.
AFTER THIS,
WORKERS APPLY A METAL TRIM
TO FINISH OFF THE FRONT
AND BACK ENDS.
THEY ALSO INSTALL A HANDLE FOR
OPENING AND CLOSING THE DOOR.
THE DOOR HANGS BY WHEELS
ATTACHED TO THE TOP PENTOGRAPH.
OPERABLE WALLS ARE MADE UP
OF SEVERAL SLIDING PANELS.
FOR EACH ONE,
WORKERS BUILD AN ALUMINUM FRAME,
THEN INSTALL
A SOUNDPROOFING MECHANISM --
A CRANK-ACTIVATED ALUMINUM SEAL
THAT JUTS OUT TO FILL THE GAP
ABOVE AND BELOW THE PANEL.
TO MAKE THE FRONT AND BACK FACES
OF EACH PANEL,
WORKERS BEGIN WITH A SHEET
OF GYPSUM BOARD.
TO ONE SIDE OF IT,
THEY GLUE A STEEL SHEET
THAT'S AT LEAST
4/100 OF AN INCH THICK.
THIS PROVIDES SOUNDPROOFING.
TO THE OTHER SIDE, THEY GLUE
A DECORATIVE SURFACE --
IN THIS CASE, LAMINATE,
A THINNER VERSION OF THE
MATERIAL USED FOR COUNTERTOPS.
A MACHINE CALLED A PINCH ROLL
APPLIES PRESSURE
TO ENSURE
THE LAMINATE ADHERES WELL.
WORKERS SLIDE THE FACE
INTO THE FRAME,
FILL IN THE MIDDLE
WITH ACOUSTICAL WOOL
FOR SOUNDPROOFING,
THEN SLIDE IN A SECOND FACING.
THEY CLOSE UP THE BOTTOM,
THEN TEST THE RETRACTABLE
SOUNDPROOFING SEAL.
THE LAST STEP
IS TO INSTALL THE WHEELS
THAT RUN ALONG THE CEILING RAIL.
AN OPERABLE WALL CAN HAVE ONE
OR MANY TYPES OF FACES --
FROM FABRIC, MIRROR,
OR GALVANIZED STEEL
TO BLACKBOARD, MARKERBOARD,
EVEN CORK BULLETIN BOARD.
IF YOU HAVE ANY COMMENTS
ABOUT THE SHOW
OR IF YOU'D LIKE TO SUGGEST
TOPICS FOR FUTURE SHOWS,
DROP US A LINE AT...
DISCOVERY COMMUNICATIONS, INC.
Narrator:
TODAY ON "HOW IT'S MADE"...
GOLF BALLS.
FURNITURE HANDLES.
PARKING METERS.
AND ROOM DIVIDERS.
DIFFERENT TYPES OF GOLF BALLS
DELIVER DIFFERENT RESULTS.
HIGHLY SKILLED GOLFERS OFTEN USE
WHAT'S CALLED A WOUND BALL --
A BALL MADE OF RUBBER THREAD
WOUND TIGHTLY OVER A CORE --
BECAUSE ITS FLIGHT
IS MORE CONTROLLABLE.
BUT MOST PEOPLE USE WHAT'S
CALLED A TWO-PIECE BALL --
A BALL WHOSE CORE IS COVERED
IN A DIMPLED MATERIAL.
TODAY'S GOLF BALL
HAS REALLY COME A LONG WAY
IF YOU CONSIDER THAT THE EARLY
ONES WERE MADE OF FEATHERS.
THIS IS WHAT'S INSIDE NOW --
A BOUNCY RUBBER.
THEY MIX IT UP WITH OTHER
CHEMICALS TO MAKE A HOT BATTER
AND THEN ROLL IT OUT
LIKE A PIE CRUST,
COOLING IT
BETWEEN TWO HUGE STEEL DRUMS.
NEXT THEY PUSH
THE ROLLED-UP RUBBERY SHEETS
INTO THIS MACHINE,
CALLED AN EXTRUDER.
THERE'S A RAM INSIDE, AND IT
FORCES THE RUBBER THROUGH A DIE.
THIS MAKES SHAPES THAT RESEMBLE
LARGE MARSHMALLOWS,
CALLED SLUGS.
A CONVEYOR BELT SENDS THEM
TO A COMPRESSION-MOLD MACHINE.
HERE A WORKER POSITIONS
THE SLUGS IN A STEEL MOLD.
THE SLUGS OFTEN VARY IN COLOR
DEPENDING ON THE TYPE OF BALL
BEING PRODUCED.
WHEN THE DOOR CLOSES,
THE BOTTOM PART OF THE MOLD
PRESSES UP INTO THE TOP PART,
APPLYING OVER A TON OF PRESSURE.
THIS IS A SHAPE-AND-BAKE SYSTEM
BECAUSE INSIDE THIS MOLD,
THE NEWLY ROUNDED RUBBER
IS COOKING
AT 332 DEGREES FAHRENHEIT.
BAKING IT FOR 13 MINUTES
HARDENS IT.
THEN AFTER IT'S COOLED
WITH WATER,
A WORKER PLACES A PIECE OF
SLOTTED PLEXIGLAS OVER THE MOLD.
THIS HOLDS DOWN
THE LEFTOVER TRIMMINGS
SO THAT ONLY THE BALL SHAPES
GET PICKED UP BY THE VACUUM.
HE PEELS OFF THE EXCESS RUBBER
FOR RECYCLING LATER.
THE MARSHMALLOW-SHAPED SLUGS
HAVE NOW BEEN TRANSFORMED
INTO A SOLID GOLF-BALL CORE.
A ROBOT TRANSPORTS THESE CORES
TO ANOTHER MOLD.
A RAM PUSHES MELTED PLASTIC
THROUGH TUBES
AND INTO A MOLD CAVITY.
THIS FORMS THE OUTSIDE SHELL
OF THE GOLF BALL,
COMPLETE WITH THE DIMPLES
THAT WILL HELP THE BALL
TRAVEL FARTHER.
THIS IS AN INSIDE LOOK AT A BALL
WITH ITS NEW SHELL.
THIS INJECTING-MOLDING SYSTEM
GENERATES FOUR DOZEN GOLF BALLS
EVERY MINUTE.
THE NEW BALLS ARE ON THE MOVE.
THEY ROLL INTO A BIN
WHICH FUNNELS THEM
TO A GOLF-BALL ELEVATOR.
THEY'RE ON THEIR WAY
TO GET CLEANED UP.
LOOK CLOSELY, AND YOU'LL SEE
LITTLE PIECES OF LEFTOVER
PLASTIC ON THE BALL SHELLS.
THE NEXT PROCESS
WILL GET RID OF THAT.
THIS IS AN AUTOMATIC MILLER
THAT REMOVES THE EXCESS PLASTIC.
THIS IS A GOLF BALL
BEFORE MILLING.
AND HERE IT IS AFTER.
THE FLECKS OF PLASTIC
HAVE BEEN REMOVED.
NEXT ROBOTIC ARMS
SHOVEL THE GOLF BALLS
TOWARDS A CHUTE ENTRY.
THIS IS A QUALITY CHECKPOINT.
IF THE BALL IS NOT SMOOTH
AND UNIFORM,
IT WON'T GO THROUGH THIS HOLE.
NOW A WHEEL ROLLS THE GOLF BALLS
TOWARDS A STAMPING MACHINE.
ROBOTIC ARMS CARRY SILICONE PADS
TO AN ETCHED STEEL PLATE.
THE PADS SOAK UP INK
FROM THE ETCHED PLATE
AND TRANSFER IT TO THE BALLS.
THE PADS BRAND EACH BALL
WITH A PLAYER NUMBER,
THE COMPANY NAME,
AND THE MODEL TYPE.
THEN BEAMS OF ULTRAVIOLET LIGHT
HARDEN THE INK.
THEY DUMP THE BALLS INTO A BIN,
BUT THEY FUNNEL SOME BALLS OVER
TO ANOTHER STAMPING MACHINE.
THIS ONE DOES CUSTOM LOGOING.
NOW, THAT'S A STAMP OF APPROVAL.
NEXT AN AUTOMATED MACHINE SPRAYS
THE BALLS WITH POLYURETHANE
WHILE THEY ROTATE ATOP SPINDLES.
THE POLYURETHANE
PROTECTS THE INK LOGOS
THAT HAVE BEEN STAMPED
ON THE BALLS.
ROBOTIC ARMS CARRY THE WET
GOLF BALLS TO A DRYING RACK,
WHERE THEY COOK AT 150 DEGREES
FAHRENHEIT FOR 5 MINUTES.
THEN THEY'RE DONE.
AND THAT'S THE TECHNIQUE
BEHIND THE GOLF BALL.
IT'S UP TO YOU TO EXPLAIN
YOUR GOLF TECHNIQUE.
Narrator: IMAGINE A DRESSER
WITH ANTIQUE-STYLE BRASS PULLS.
NOW IMAGINE THAT SAME DRESSER
WITH COUNTRY-STYLE WOODEN KNOBS
OR FUNKY PLASTIC KNOBS OR SLEEK
HANDLES IN STAINLESS STEEL.
THE DECORATIVE HARDWARE
ON A PIECE OF FURNITURE
OR ON CABINETRY
DRAMATICALLY AFFECTS ITS LOOK,
SO CHANGING THEM IS AN EASY
AND INEXPENSIVE MAKEOVER.
HOW WOULD WE GET A GRIP
ON THINGS
WITHOUT KNOBS AND HANDLES?
THEY'RE MORE THAN SOMETHING
THAT CAN OPEN DOORS FOR YOU.
THE MANY STYLES ADD
TO THE APPEAL OF OUR FURNITURE.
TO MAKE A HANDLE, AN ELECTRICAL
HOIST DROPS BIG CHUNKS OF ZINC
INTO A MELTING FURNACE.
AT 800 DEGREES FAHRENHEIT,
METAL QUICKLY TURNS INTO LIQUID.
IT'S SO HOT, YOU'D LOSE A FINGER
IF YOU TOUCHED IT.
AUTOMATED ARMS MOVE AN IRON POT
FULL OF THE LIQUID
TO A RAILROAD CAR,
WHICH TAKES IT
TO THE NEXT STAGE.
HERE THEY POUR THE LIQUID METAL
INTO ANOTHER FURNACE
THAT'S JUST AS HOT.
THIS IS CALLED
A MACHINE FURNACE.
A HYDRAULICALLY DRIVEN CYLINDER
PUSHES THE LIQUID METAL
THROUGH A SYSTEM OF NOZZLES
AND PIPES
THAT RUN THROUGH THE FURNACE.
IT CARRIES THE LIQUID METAL
TO A DIE.
THE DIE SHAPES THE HANDLES
COOKIE-CUTTER STYLE.
WATER FLUSHES THROUGH THE DIE.
THIS COOLS DOWN THE ZINC,
AND IT HARDENS
INTO A HANDLE SHAPE
WITH A LOT OF EXTRA MOLDING
THAT THEY'RE GOING TO HAVE
TO GET RID OF.
SO, NOW THAT THEY'VE COOLED,
IT'S SAFE TO TOUCH THEM
AND REMOVE SOME OF THAT WASTE.
A WORKER SNAPS SOME OF IT OFF
AND TOSSES IT INTO A BIN
FOR RECYCLING LATER,
AND THE HANDLE SHAPES
GO INTO A SEPARATE BIN.
BUT THERE ARE STILL SOME LITTLE
BITS OF WASTE ON THE HANDLES
CALLED OVERFLOWS,
SO A MECHANICALLY DRIVEN SPINNER
TOSSES THE HANDLES AROUND
AND KNOCKS OFF ANY OVERFLOWS
THAT HAVE BEEN MISSED.
IT'S A LOT FASTER THAN PICKING
OFF THOSE LITTLE PIECES BY HAND.
A WORKER DUMPS THE HANDLE SHAPES
INTO A BIN.
THEY'RE DEFINITELY STARTING
TO TAKE SHAPE NOW.
A SIMILAR DIE-CASTING SYSTEM
IS USED TO MAKE KNOBS,
BUT THE KNOBS COME
IN TWO INTERLOCKING PIECES.
THEY PLACE THEM ON A TURNTABLE
AND FIT THEM TOGETHER.
THEN A 4-TON HYDRAULIC PRESS
PRESSES DOWN ON THE KNOB,
AND THAT PRESSURE SEALS THEM.
THEY POUR A MIXTURE
OF WATER AND OIL ON THE KNOBS
TO COOL AND LUBRICATE THEM,
WHILE AN AUTOMATED MACHINE
DRIVES A SCREW INTO THE BACK
OF THE KNOB.
THIS MAKES A THREAD PATTERN
INSIDE OF IT
SO IT CAN BE EASILY SCREWED
ONTO FURNITURE LATER.
NOW THEY PLUNGE THE HANDLES
INTO A CHEMICAL BATH.
THE CHEMICALS HELP
TO CONDUCT ELECTRICITY.
THIS PROCESS
IS CALLED ELECTROPLATING.
THE HANDLES
ARE NEGATIVELY CHARGED.
THE BRASS PARTICLES IN THE WATER
ARE POSITIVELY CHARGED.
THEY ATTRACT AND CONNECT,
AND THIS CAUSES
THE BRASS PLATING TO FORM.
THEY DIP THE HANDLES
INTO THE CHEMICAL WASH TWICE
AND THEN RINSE TWICE.
NEXT THEY DUMP THE BRASS HANDLES
INTO A VAT OF ACID.
THIS OXIDIZES IT,
BLACKENING THE FINISH
TO MAKE IT LOOK ANTIQUE.
THIS BRASS PULL HAS AGED
A HUNDRED YEARS
IN JUST A FEW MINUTES.
NEXT THEY FUNNEL THE HANDLES
INTO A BIG, ROUND POLISHER.
IT'S CALLED A BOWL VIBRATOR.
THE HANDLES ARE MIXED IN
WITH STEEL BALL BEARINGS.
THE MACHINE VIBRATES,
AND THE FRICTION FROM THE BALL
BEARINGS POLISHES THE HANDLES.
NOW THOSE ANTIQUE BRASS HANDLES
HAVE A SHINIER FINISH.
SOMETIMES THEY USE
CERAMIC PELLETS IN THE POLISHER
INSTEAD OF BALL BEARINGS.
THEY SPRAY SOAP AND WATER
INTO THE BOWL
TO LUBRICATE THE HANDLES
AND ALLOW THEM TO MOVE FREELY.
THIS GENTLER FRICTION
RESULTS IN A DIFFERENT FINISH.
THE POLISH ON THE HANDLES
WILL BE BRIGHTER.
NOW THEY PUT A HANDLE
INTO A CLAMP.
WITH AIR PRESSURE,
IT SQUEEZE THE HANDLE
SO THAT IT HOOKS
INTO A BACKPLATE.
WHEN THE PRESSURE IS RELEASED,
THE FIT IS SNUG.
A FRONT AND BACKPLATE GIVES
A HANDLE A MORE ELABORATE LOOK.
THEY BUFF UP A KNOB
WITH A CLOTH POLISHING WHEEL
THAT'S MECHANICALLY DRIVEN.
THIS PROCESS GIVES KNOBS
AND HANDLES A CERTAIN GLEAM.
IT'S THE FINISHING TOUCH.
Narrator:
THE BEATLES WROTE A SONG ABOUT
LOVELY RITA THE METER MAID,
BUT TRY FINDING ANYONE ELSE
SINGING THE PRAISES
OF THOSE UNIFORMED PATROLS
WHO TICKET YOUR CAR
WHEN YOUR METER EXPIRES.
PARKING METERS HAVE BEEN AROUND
SINCE THE 1930s,
AND EVER SINCE THEN, DRIVERS
HAVE HAD TO PAY FOR PARKING.
IT'S TIME TO FIND OUT
JUST HOW THESE HEAVY-DUTY
PIGGY BANKS ARE MADE.
FIRST THE LOW-TECH PART.
THE TIME-LIMIT LABEL GOES
ONTO A ZINC DOME-SHAPED PLATE.
THEN A WORKER SPRAYS LUBRICANT
ONTO VARIOUS PARTS
OF THE MOTHERBOARD
THAT CONTAINS
COMPUTER CIRCUITRY.
AFTER HE SNAPS THE BOARD
ONTO THE PLATE, HE SCREWS IT IN.
THEN HE FASTENS ANOTHER
DOME-SHAPED PLATE ONTO THE BACK,
SANDWICHING THE MOTHERBOARD
BETWEEN THE TWO PLATES.
THE WORKER HOOKS THE BOARD UP
TO THE POWER SOURCE --
THE BATTERY PACK --
AND HE TUCKS THE PACK
INTO A SPECIAL COMPARTMENT
SO THAT IT'S SECURE.
THEN HE PLUGS A PROGRAMMING
DEVICE CALLED AN "X" KEY
INTO PRONGS PROTRUDING
FROM THE MOTHERBOARD.
THE KEY FEEDS SOFTWARE
TO THE MOTHERBOARD INSIDE.
WHEN NUMBERS APPEAR
ON THE SCREEN, IT'S PROGRAMMED.
THE NEXT PIECE,
CALLED A SmartChute,
ALSO HAS COMPUTER CIRCUITRY.
IT ANALYZES THE COINS
AS THEY FALL THROUGH THE METER.
IT CAN EVEN RECOGNIZE COINS
FROM OTHER COUNTRIES.
HE PUTS THE CHUTE INTO
A PROTECTIVE PLASTIC CASING
AND PLUGS IT
INTO THE PROTRUDING PRONGS
THAT WERE USED EARLIER
TO PROGRAM THE METER.
THE TWO BOARDS
MAKE A CONNECTION
AND CAN NOW COMMUNICATE
TO ONE ANOTHER.
HE CLICKS ANOTHER ZINC PLATE
OVER THE COIN CHUTE
AND ADDS A STAINLESS-STEEL
COIN SLOT FOR ADDED PROTECTION.
THIS CARD
IS A RADIO-FREQUENCY PROBE
THAT DETECTS HOW MUCH MONEY
IS IN THE METER
AS WELL AS
MAINTENANCE INFORMATION.
JUST HOW GOOD IS A PARKING METER
AT ANALYZING COINS?
THIS PARTICULAR METER
WAS MADE IN CANADA.
A CANADIAN NICKEL
AND A BRITISH 20 PENCE
ARE ROUGHLY THE SAME SIZE.
PUT IN A CANADIAN NICKEL,
AND YOU GET THREE MINUTES.
BUT TRY THE 20 PENCE.
NOTHING REGISTERS.
THE METER TREATS IT
LIKE A PLUG NICKEL.
THE METERS ARE NOW
IN AN ENVIRONMENTAL CHAMBER.
THIS CHAMBER REPLICATES THE MOST
EXTREME CLIMATE CONDITIONS.
IT'S A TEST TO MAKE SURE THEY'RE
READY FOR LIFE ON THE STREET.
NOW IT'S TIME TO MAKE A LOCK.
HE PUTS A ZINC-ALLOY LOCK PLUG
CONTAINING BRASS TUMBLERS
INTO A MINIATURE LATHE.
THE LATHE SPINS RAPIDLY
ON ITS AXIS
WHILE PRESSING
AGAINST THE HARD STEEL BLADES.
THE BLADES CUT
THE SPINNING LOCK TUMBLERS
TO THE APPROPRIATE LENGTH.
THE RESULT?
A LOCK PLUG THAT HAS BRASS
TUMBLERS OF DIFFERENT LENGTHS
THAT CAN'T BE OPENED
WITHOUT THE CORRECT KEY.
HERE A WORKER PLACES
THE LOCK BARREL IN A VISE
TO GIVE A BETTER VIEW
OF THE LOCK SYSTEM.
AS YOU CAN SEE,
IT TURNS EASILY WITH THE KEY.
BUT, VANDALS, BEWARE.
THIS LOCK IS DESIGNED
TO BE TOUGH TO PICK.
NEXT HE INSERTS THE LOCK
INTO THE BOTTOM OF A COIN CAN
THAT'S MADE OF PLASTIC.
HE CLOSES IT
AND THEN PUTS IT ON WHAT'S
CALLED A SONIC WELDING MACHINE.
IT EMITS HIGH-FREQUENCY
SOUND VIBRATIONS
THAT ACTUALLY MELT
THE RIGID PLASTIC,
WELDING THE TOP
AND BOTTOM PIECES TOGETHER.
NOW THESE COINS WILL BE
REALLY TOUGH TO GET OUT
WITHOUT THAT KEY.
NEXT HE BRUSHES A SECOND LOCK
SYSTEM WITH A LUBRICANT
AND ADDS A HARD STEEL SHIELD
THAT WILL RESIST ATTEMPTS
TO DRILL INTO IT.
THIS LOCK GOES ONTO AN IRON DOOR
WHICH WILL BE PART OF THE VAULT
THAT CONTAINS THE COIN CAN.
HE BRUSHES THE LOCK ASSEMBLY
WITH ANOTHER LUBRICANT
TO MAKE THE LOCKING OPERATION
SMOOTHER.
THEN HE INSTALLS A RUBBER GASKET
ALONG THE FRAME
FOR THE METER DOME WINDOW.
THIS GASKET SEALS THE DOME
AND PROTECTS THE ELECTRONICS
FROM HARSH WEATHER.
HE PLACES A TOUGH PLASTIC WINDOW
ON THE GASKET
AND TOPS IT WITH A ZINC STRAP.
HE SCREWS ALL THE PIECES
TOGETHER.
THEN HE PLACES THE IRON CASE
THAT WILL HOLD ALL THE MECHANICS
ON TOP OF THE VAULT
CONTAINING THE COIN CAN.
HE ATTACHES THE WINDOWED CAP
AND STRAP ASSEMBLY WITH HINGES.
AND THERE'S A THIRD LOCK
TO HELP PROTECT THE ELECTRICAL
COMPONENTS OF THE PARKING METER.
AFTER A CHECK
FOR FIT AND FUNCTION,
HE INSTALLS
THE ACTUAL MECHANICS.
THIS MEANS IT'S ALL SYSTEMS GO.
THE PARKING METER IS READY
FOR THE STREET.
LATER THE COINS CAN BE COLLECTED
WITHOUT EVEN OPENING
THE PLASTIC COIN CAN.
THIS SPECIAL RECEPTACLE
ACTIVATES THE LOCK
AT THE BOTTOM OF THE CAN.
ONCE TURNED, THE COINS DEPOSITED
INTO THE PARKING METER
DROP INTO THE RECEPTACLE.
Narrator: IF YOU NEED
TO SECTION OFF PART OF A ROOM,
THERE ARE MANY TYPES OF ROOM
DIVIDERS THAT CAN DO THE JOB.
ACCORDION DOORS ROUTINELY DIVIDE
MEETING ROOMS.
SLIDING WALLS MADE UP
OF MULTIPLE PANELS
CAN EASILY SPLIT
A LARGE RECEPTION HALL IN HALF
OR PARTITION AN OFFICE
IN NO TIME AT ALL.
THIS PARTICULAR COMPANY MAKES
TWO TYPES OF ROOM DIVIDERS --
SLIDING PANELS
CALLED OPERABLE WALLS
AND ACCORDION DOORS.
BOTH HAVE
BUILT-IN SOUNDPROOFING.
THE FOLDING MECHANISM
AT THE CORE OF AN ACCORDION DOOR
IS CALLED A PANTOGRAPH.
IT'S MADE OF FLAT STEEL BARS
RIVETED TOGETHER
IN A CRISSCROSS CONFIGURATION.
A WORKER TIGHTENS THE RIVETS
JUST ENOUGH TO HOLD THE BARS
IN POSITION
WITHOUT IMPEDING THEIR MOVEMENT.
THEN HE INSERTS PINS
ALONG THE TOP AND BOTTOM,
SECURING THEM
WITH STEEL RETAINING RINGS.
THE PANTOGRAPH IS CUSTOM-BUILT
TO EXPAND TO THE PRECISE WIDTH
OF THE DOOR THEY'RE MAKING,
THE PINS ATTACHED TO THE COVERS
THAT WILL LATER
SANDWICH THE PANTOGRAPH,
FORMING THE ACCORDION DOOR'S
SURFACE.
TO MAKE THOSE COVERS,
THEY FIRST MAKE SLATS.
THIS AUTOMATED MACHINE
HOT-GLUES A BAND OF CARDBOARD
ONTO A BAND OF STEEL.
THEN A SERIES OF ROLLERS
PROGRESSIVELY FOLDS
THE SIDES UPWARD,
FORMING A STEEL EDGE
AROUND THE CARDBOARD.
FINALLY THE MACHINE CUTS
THE CONTINUOUS BAND INTO SLATS,
WHOSE LENGTH IS THE HEIGHT
OF THE ACCORDION DOOR
THEY'RE MAKING.
NOW WORKERS PAIR UP THE SLATS,
CONNECTING THEM
WITH CARDBOARD STRIPS.
THEY FEED EACH PAIR
INTO A GLUE MACHINE.
THE SLATS COME OUT ADHERED
TO A SOFT AND FLEXIBLE TYPE
OF PAPER THAT'S TEARPROOF.
NEXT WORKERS CONNECT SIX PAIRS
OF SLATS TO FORM A PANEL.
THEN THEY GLUE ON
THE DECORATIVE SURFACE --
IN THIS CASE,
COMMERCIAL-QUALITY VINYL.
TO BLOCK SOUND FROM PASSING
THROUGH THE SPACE
ABOVE AND BELOW
THE ACCORDION DOOR,
A WORKER GLUES
A FELT-AND-VINYL STRIP
TO THE TOP AND BOTTOM
OF EACH PANEL.
AFTER LINING THE INSIDE OF EACH
PANEL WITH ACOUSTIC WOOL,
A SOUNDPROOFING MATERIAL,
ANOTHER WORKER GATHERS
THE NUMBER OF PANELS
REQUIRED FOR THE DOOR'S WIDTH.
HE ATTACHES THEM
USING INDUSTRIAL-STRENGTH
STEEL STAPLES.
THEN HE SLIPS
U-SHAPED STEEL CHANNELS
ONTO WHAT WILL BE
THE DOOR'S INSIDE FOLDS.
USING AN AIR-POWERED MACHINE
CALLED A SERTER,
HE PRESSES THE CHANNELS TIGHTLY
IN PLACE.
NOW HE INSTALLS THE PENTOGRAPHS.
THE HEIGHT OF THE DOORS
DETERMINE HOW MANY.
USING STEEL RETAINING RINGS,
HE LOCKS THE PENTOGRAPH PINS
INTO HOLES ON THE CHANNELS.
THE SECOND COVER GOES ON
THE SAME WAY.
AFTER THIS,
WORKERS APPLY A METAL TRIM
TO FINISH OFF THE FRONT
AND BACK ENDS.
THEY ALSO INSTALL A HANDLE FOR
OPENING AND CLOSING THE DOOR.
THE DOOR HANGS BY WHEELS
ATTACHED TO THE TOP PENTOGRAPH.
OPERABLE WALLS ARE MADE UP
OF SEVERAL SLIDING PANELS.
FOR EACH ONE,
WORKERS BUILD AN ALUMINUM FRAME,
THEN INSTALL
A SOUNDPROOFING MECHANISM --
A CRANK-ACTIVATED ALUMINUM SEAL
THAT JUTS OUT TO FILL THE GAP
ABOVE AND BELOW THE PANEL.
TO MAKE THE FRONT AND BACK FACES
OF EACH PANEL,
WORKERS BEGIN WITH A SHEET
OF GYPSUM BOARD.
TO ONE SIDE OF IT,
THEY GLUE A STEEL SHEET
THAT'S AT LEAST
4/100 OF AN INCH THICK.
THIS PROVIDES SOUNDPROOFING.
TO THE OTHER SIDE, THEY GLUE
A DECORATIVE SURFACE --
IN THIS CASE, LAMINATE,
A THINNER VERSION OF THE
MATERIAL USED FOR COUNTERTOPS.
A MACHINE CALLED A PINCH ROLL
APPLIES PRESSURE
TO ENSURE
THE LAMINATE ADHERES WELL.
WORKERS SLIDE THE FACE
INTO THE FRAME,
FILL IN THE MIDDLE
WITH ACOUSTICAL WOOL
FOR SOUNDPROOFING,
THEN SLIDE IN A SECOND FACING.
THEY CLOSE UP THE BOTTOM,
THEN TEST THE RETRACTABLE
SOUNDPROOFING SEAL.
THE LAST STEP
IS TO INSTALL THE WHEELS
THAT RUN ALONG THE CEILING RAIL.
AN OPERABLE WALL CAN HAVE ONE
OR MANY TYPES OF FACES --
FROM FABRIC, MIRROR,
OR GALVANIZED STEEL
TO BLACKBOARD, MARKERBOARD,
EVEN CORK BULLETIN BOARD.
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