Ex parte ARCHIBALD et al. - Page 14

          Appeal No. 1998-1289                                                        
          Application 07/906,492                                                      

                 Adams, the primary reference in these rejections,                    
            discloses “a method of manufacturing a wheel having a                     
            load supporting disc portion and at least a part of a rim                 
            portion formed together as a seamless unitary structure                   
            from a single metal blank” (column 1, lines 44 through                    
            47).  Of particular interest are the process steps                        
            depicted in Figures 4a through 4f whereby                                 

                 [a] blank 60 is formed by circling a band of                         
                 even gauge hot rolled strip and joining the ends                     
                 by electric butt welding.  The ends of the blank                     
                 are flared by conventional methods and pressed                       
                 in two stages as shown in FIGURES 4b and 4c to                       
                 form the flanges 61 of a channel section.  The                       
                 base 62 and the outside of the flanges are                           
                 supported by formers 63 and 63a (FIGURE 4c) and                      
                 a contoured roller 64 is brought into contact                        
                 with the blank to apply pressure to the outer                        
                 peripheral edges of the flanges 61 to thicken up                     
                 the junctions of the flanges 61 with the base                        
                 62, and to radius the edges of the flanges.  The                     
                 roller 64 also produces a circumferentially                          
                 extending groove 65 (see FIGURE 4d) suitably                         
                 positioned for subsequent parting of the blank                       
                 into a rim part 67 with a tyre-retaining flange                      
                 intergal [sic] with it and a loose flange 68.                        
                 The formers 63, 63a may move axially during the                      
                 rolling operation.  The parting operation may be                     
                 carried out with punches 66 as indicated in                          
                 FIGURE 4d.  The final shapes of the flanges are                      
                 imposed by pressing the separate parts 67 and 68                     
                 as shown in FIGURE 4e, between formers 69, 69a                       
                 the final form of the parts 67, 68 being shown                       

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