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Narrator: IF YOU SUFFER FROM
OSTEOARTHRITIS OF THE KNEE,
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00:00:55,931 --> 00:00:58,413
YOUR DOCTOR MIGHT PRESCRIBE
A KNEE BRACE.
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00:00:58,413 --> 00:01:00,724
OSTEOARTHRITIS
IS WHEN THE CARTILAGE
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00:01:00,724 --> 00:01:03,034
CUSHIONING THE KNEE JOINT
WEARS OUT,
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00:01:03,034 --> 00:01:05,862
CAUSING BONE TO PAINFULLY
RUB ON BONE.
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00:01:05,862 --> 00:01:08,448
A BRACE RELIEVES
SOME OF THAT PAIN
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00:01:08,448 --> 00:01:12,413
BY REALIGNING THE LEG TO SHIFT
WEIGHT OFF THE KNEE JOINT.
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00:01:14,551 --> 00:01:17,758
THIS DUAL-ACTION KNEE BRACE
ROTATES THE FOOT,
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00:01:17,758 --> 00:01:20,448
WHICH MOVES THE THIGHBONE,
THE FEMUR,
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00:01:20,448 --> 00:01:24,137
OFF THE MOST PAINFUL AREA
OF THE SHINBONE, THE TIBIA.
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00:01:24,137 --> 00:01:27,034
IT ALSO CREATES WHAT'S CALLED
A DISTRACTION,
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00:01:27,034 --> 00:01:29,793
PULLING THE FEMUR AND TIBIA
SLIGHTLY APART
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00:01:29,793 --> 00:01:32,344
TO FURTHER REDUCE STRESS
ON THE JOINT.
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00:01:32,344 --> 00:01:35,482
THE BRACE IS CUSTOM-MADE
FOR EACH PATIENT.
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00:01:35,482 --> 00:01:38,206
AN ORTHOTIST TAKES
THE MEASUREMENTS
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00:01:38,206 --> 00:01:41,137
BY PASSING A SOPHISTICATED
3-D SCANNER
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00:01:41,137 --> 00:01:44,689
APPROXIMATELY 12 INCHES ABOVE
AND BELOW THE KNEE.
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00:01:44,689 --> 00:01:48,827
THE SCANNER TRANSLATES THE DATA
INTO A 3-D COMPUTER IMAGE
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00:01:48,827 --> 00:01:52,344
WITH HIGHLY SPECIALIZED
MEDICAL-DEVICE SOFTWARE,
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00:01:52,344 --> 00:01:56,172
THEN PROCESSES THAT IMAGE
INTO ANATOMICAL BLUEPRINTS
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00:01:56,172 --> 00:01:57,482
FOR A 3-D MODEL.
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00:01:57,482 --> 00:02:00,000
THE COMPUTER
THEN READS THE PLANS
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00:02:00,000 --> 00:02:03,620
AND GUIDES THIS CARVING MACHINE
TO CREATE THE MODEL
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00:02:03,620 --> 00:02:06,172
FROM A BLOCK
OF HIGH-DENSITY FOAM.
25
00:02:06,172 --> 00:02:10,000
THE CARVING PROCESS
TAKES ABOUT 10 MINUTES.
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00:02:12,275 --> 00:02:16,344
THE FINISHED MODEL IS AN EXACT
REPLICA OF THE PATIENT'S LEG,
27
00:02:16,344 --> 00:02:19,310
WHICH TECHNICIANS NOW USE
TO CONSTRUCT A BRACE
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00:02:19,310 --> 00:02:21,517
THAT FITS THE PATIENT PERFECTLY.
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00:02:22,724 --> 00:02:25,448
AFTER WRAPPING THE MODEL
IN PLASTIC FILM
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00:02:25,448 --> 00:02:27,000
TO PROTECT THE SURFACE
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00:02:27,000 --> 00:02:30,517
AND MARKING THE MAIN ANATOMICAL
LANDMARKS OF THE KNEE,
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00:02:30,517 --> 00:02:33,310
THEY LAY A THICK FOAM BAND
OVER THE TIBIA
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00:02:33,310 --> 00:02:35,655
AND BEGIN MARKING
WHERE THEY'LL INSTALL
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00:02:35,655 --> 00:02:37,275
THE TWO ARTICULATION HINGES,
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00:02:37,275 --> 00:02:40,344
WHICH ROTATE THE FOOT AND
DISTRACT THE FEMUR AND TIBIA.
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00:02:40,344 --> 00:02:43,172
THIS TEMPLATE IS
FOR THE LATERAL HINGE,
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00:02:43,172 --> 00:02:44,689
THE PRIMARY ROTATOR.
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00:02:44,689 --> 00:02:47,586
IT'S SITUATED
ON THE OUTSIDE OF THE LEG.
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00:02:47,586 --> 00:02:51,724
NEXT, TAKING AN ALUMINUM BAR
AND BENDING IT ON SPECIAL TOOLS,
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00:02:51,724 --> 00:02:55,068
THE TECHNICIANS FORM
THE BRACE'S TIBIAL CROSSBAR,
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00:02:55,068 --> 00:02:58,586
THE BAND THAT CROSSES THE SHIN
AND HOLDS THE TWO HINGES.
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00:02:58,586 --> 00:03:02,068
THE FOAM BAND TAKES UP THE SPACE
OF A SILICONE LINING
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00:03:02,068 --> 00:03:04,758
THAT WILL GO UNDER
THE TIBIAL CROSSBAR --
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00:03:04,758 --> 00:03:07,758
CRITICAL CUSHIONING TO PREVENT
PRESSURE POINTS
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00:03:07,758 --> 00:03:09,724
THAT CAN CAUSE SKIN IRRITATION.
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00:03:09,724 --> 00:03:12,275
ONCE THE CROSS BAR
FITS PERFECTLY,
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00:03:12,275 --> 00:03:14,068
THEY REAPPLY THE TEMPLATE
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00:03:14,068 --> 00:03:17,689
AND MARK WHERE RIVETS
WILL ATTACH THE LATERAL HINGE.
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00:03:17,689 --> 00:03:22,206
THEN, USING THE SAME
METAL BENDING TOOLS
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00:03:22,206 --> 00:03:24,310
THEY USED TO SHAPE THE CROSSBAR,
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00:03:24,310 --> 00:03:27,965
THEY CONTOUR THE HINGE TO FOLLOW
THE SHAPE OF THE LEG.
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00:03:29,137 --> 00:03:32,758
THEY ATTACH THE LATERAL HINGE
TO THE TIBIAL CROSSBAR
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00:03:32,758 --> 00:03:34,206
WITH COPPER RIVETS.
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00:03:34,206 --> 00:03:36,034
COPPER IS A SOFT METAL,
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00:03:36,034 --> 00:03:39,689
SO THEY CAN COMPACT IT
TO PRODUCE A SOLID JOINT,
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00:03:39,689 --> 00:03:42,793
WHICH WON'T LOOSEN UP OVER TIME
WITH REPEATED USE.
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00:03:42,793 --> 00:03:45,379
AT THE OTHER END
OF THE CROSSBAR,
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00:03:45,379 --> 00:03:49,551
THEY AFFIX THE MEDIAL HINGE,
WHICH PRODUCES THE DISTRACTION.
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00:03:49,551 --> 00:03:51,448
WHEN THE KNEE IS EXTENDED,
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00:03:51,448 --> 00:03:55,862
THIS HINGE LENGTHENS THE BRACE
BY APPROXIMATELY 3/4 OF AN INCH,
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00:03:55,862 --> 00:03:58,931
PULLING THE TIBIA
AND FEMUR SLIGHTLY APART
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00:03:58,931 --> 00:04:00,344
TO ELIMINATE PAIN.
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00:04:00,344 --> 00:04:03,034
IT'S TIME TO MOLD
THE PLASTIC SHELL,
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00:04:03,034 --> 00:04:06,586
THE UPPER PART OF THE BRACE
THAT FITS ONTO THE THIGH.
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00:04:06,586 --> 00:04:10,379
FIRST, THEY SOFTEN A FOAM SHEET
IN A LOW-TEMPERATURE OVEN
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00:04:10,379 --> 00:04:12,206
AND WRAP IT AROUND THE MODEL.
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00:04:12,206 --> 00:04:15,034
THIS TAKES UP THE SPACE
OF THE FABRIC LINING
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00:04:15,034 --> 00:04:17,103
THAT WILL GO UNDER THE PLASTIC.
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00:04:17,103 --> 00:04:20,344
AFTER COVERING THE FOAM
IN A COTTON HEAT BARRIER,
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00:04:20,344 --> 00:04:23,068
THEY SOFTEN A PLASTIC SHEET
IN THE OVEN,
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00:04:23,068 --> 00:04:24,758
WRAP IT AROUND THE MODEL,
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00:04:24,758 --> 00:04:28,103
STAPLE THE ENDS TOGETHER,
73
00:04:28,103 --> 00:04:29,793
THEN COAT THE SURFACE IN TALC,
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00:04:29,793 --> 00:04:32,172
WHICH PREVENTS THEIR GLOVES
FROM STICKING
75
00:04:32,172 --> 00:04:33,620
WHEN THEY APPLY PRESSURE.
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00:04:33,620 --> 00:04:35,793
ONCE THE PLASTIC COOLS,
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00:04:35,793 --> 00:04:39,931
THEY TRACE THE SHELL'S SHAPE
AND CUT IT OUT.
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00:04:39,931 --> 00:04:43,000
THEN, THEY WRAP IT
IN A PROTECTIVE VINYL FINISH,
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00:04:43,000 --> 00:04:45,896
HEATING THE MATERIAL
SO THAT IT BECOMES STICKY
80
00:04:45,896 --> 00:04:47,655
AND ADHERES TO THE PLASTIC.
81
00:04:50,620 --> 00:04:54,620
THEY ALSO WRAP
THE TIBIAL CROSSBAR IN VINYL.
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00:04:58,000 --> 00:05:01,931
THEN THEY APPLY A STRIP
OF VELCRO TO THE UNDERSIDE,
83
00:05:01,931 --> 00:05:04,758
WHERE THEY'LL LATER
ADHERE PADDING.
84
00:05:06,689 --> 00:05:11,655
THEY INSTALL A COVER OVER EACH
HINGE TO PROTECT THE MECHANISM.
85
00:05:11,655 --> 00:05:15,931
THEN THEY CUT A FABRIC LINING
FOR THE UPPER PART OF THE BRACE.
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00:05:15,931 --> 00:05:18,689
IT ADHERES TO THE PLASTIC
WITH VELCRO
87
00:05:18,689 --> 00:05:21,241
SO THAT IT'S REMOVABLE
FOR WASHING
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00:05:21,241 --> 00:05:23,448
OR FOR REPLACEMENT
WHEN WORN OUT.
89
00:05:24,862 --> 00:05:27,758
THE BRACE APPLIES THE GREATEST
AMOUNT OF PRESSURE
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00:05:27,758 --> 00:05:29,275
AT THE TIBIAL CROSSBAR,
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00:05:29,275 --> 00:05:32,689
SO THEY LINE THE CROSSBAR WITH
SILICONE PADDING FOR COMFORT.
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00:05:32,689 --> 00:05:35,000
THE PAD ATTACHES
TO THE VELCRO STRIP.
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00:05:36,965 --> 00:05:41,034
THE BRACE FASTENS TO THE LEG
WITH THREE ADJUSTABLE STRAPS
94
00:05:41,034 --> 00:05:44,137
AND WORKS ONLY WHEN THE KNEE
IS EXTENDED,
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00:05:44,137 --> 00:05:47,586
WHICH IS WHEN OSTEOARTHRITIC
PAIN HITS THE MOST.
96
00:06:02,620 --> 00:06:05,034
Narrator:
THE DUCTLESS AIR CONDITIONER,
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00:06:05,034 --> 00:06:06,862
INVENTED IN JAPAN IN THE 1970s,
98
00:06:06,862 --> 00:06:09,103
TRANSFORMS HOMES
INTO COOL SPACES.
99
00:06:09,103 --> 00:06:11,793
THIS SYSTEM CONSISTS
OF AN OUTSIDE CONDENSER
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00:06:11,793 --> 00:06:14,862
AND REFRIGERANT LINES THAT RUN
TO A FAN IN THE WALL.
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00:06:14,862 --> 00:06:16,896
IN HOMES WITHOUT DUCTWORK,
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00:06:16,896 --> 00:06:20,034
IT PROVIDES COOLING
WITHOUT RENOVATIONS.
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00:06:22,620 --> 00:06:24,655
NO CENTRAL AIR?
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00:06:24,655 --> 00:06:28,000
DUCTLESS AIR CONDITIONERS,
ALSO KNOWN AS MINI-SPLITS,
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00:06:28,000 --> 00:06:30,000
ARE A COOL OPTION.
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00:06:32,310 --> 00:06:36,551
TO MANUFACTURE THE CONDENSER,
THEY START WITH COPPER TUBING.
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00:06:36,551 --> 00:06:39,103
IT WILL BE USED
TO MAKE THE COILS
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THAT COOL AND CONDENSE
THE REFRIGERANT.
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00:06:42,103 --> 00:06:45,793
A MACHINE UNWINDS SIX REELS
OF TUBING SIMULTANEOUSLY
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00:06:45,793 --> 00:06:48,620
AND PULLS THEM BETWEEN ROLLERS.
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00:06:48,620 --> 00:06:51,000
THEY IRON OUT THE KINKS.
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00:06:51,000 --> 00:06:55,965
LITTLE ROTATING KNIVES CUT THE
TUBING TO THE CORRECT LENGTH.
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00:06:55,965 --> 00:06:59,724
THE CUT TUBES EXIT INTO A DEVICE
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00:06:59,724 --> 00:07:02,068
THAT BENDS THEM
AROUND A MANDRILL.
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00:07:09,931 --> 00:07:14,448
THIS CREATES HAIRPIN BENDS
IN THE CENTER OF EACH TUBE,
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00:07:14,448 --> 00:07:18,793
AND THEY END UP LOOKING
LIKE BIG COPPER BOBBY PINS.
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00:07:24,275 --> 00:07:29,068
NEXT, A SHEET OF ALUMINUM
FEEDS INTO A PROGRESSIVE DIE.
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00:07:32,241 --> 00:07:36,517
A PRESS MOVES UP AND DOWN TO
DRIVE THE METAL INTO THE DIE.
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00:07:36,517 --> 00:07:37,965
WITH EACH STROKE,
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00:07:37,965 --> 00:07:41,827
THE ALUMINUM IS SHAPED
INTO A PART KNOWN AS A FIN.
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00:07:41,827 --> 00:07:44,620
THEY'LL USE A HUNDRED
OR MORE FINS
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00:07:44,620 --> 00:07:46,793
IN ONE AIR CONDITIONER COIL.
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00:07:46,793 --> 00:07:50,827
THE FINS FALL OUT OF THE PRESS
INTO NEAT STACKS.
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00:07:52,137 --> 00:07:55,379
A WORKER SLIDES METAL RODS
INTO THE STACKS
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00:07:55,379 --> 00:07:57,758
TO MAINTAIN THE ALIGNMENT
OF THE FINS
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00:07:57,758 --> 00:08:00,310
AND ADDS A STEEL END PLATE.
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00:08:00,310 --> 00:08:03,517
SHE NOW INSERTS
THE HAIRPIN COPPER TUBING
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00:08:03,517 --> 00:08:05,620
FOLLOWING A PRECISE PATTERN.
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00:08:05,620 --> 00:08:08,827
THE FINS WILL ACT AS A KIND
OF WEB FOR THE TUBES.
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00:08:08,827 --> 00:08:11,379
THEY'RE AN IMPORTANT PART
OF THE COIL,
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00:08:11,379 --> 00:08:13,931
ALLOWING HEAT
FROM THE REFRIGERANT GAS
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00:08:13,931 --> 00:08:17,068
TO BE DISSIPATED MORE QUICKLY.
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00:08:17,068 --> 00:08:20,413
NEXT, A PRESS DRIVES MANDRILLS
INTO THE TUBES,
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00:08:20,413 --> 00:08:24,034
EXPANDING THEM SO THEY'LL FIT
TIGHTER TO THE FINS.
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00:08:25,551 --> 00:08:27,758
THE COIL HAS REALLY TAKEN SHAPE.
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00:08:27,758 --> 00:08:29,310
AT THE NEXT STATION,
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00:08:29,310 --> 00:08:32,655
THEY LOAD IT INTO A HYDRAULIC
BENDING MACHINE.
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00:08:35,379 --> 00:08:39,862
IT BENDS ONE SECTION OF THE COIL
AROUND A METAL FORM.
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00:08:41,586 --> 00:08:45,413
THIS GIVES THE COIL A MORE
CURVED PROFILE ON ONE SIDE
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00:08:45,413 --> 00:08:48,724
SO IT WILL FIT
IN THE CONDENSING UNIT LATER.
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00:08:54,862 --> 00:08:57,793
THEY CLOSE THE OPEN END
OF THE COPPER TUBES
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00:08:57,793 --> 00:08:59,413
WITH U-BEND CONNECTORS.
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00:08:59,413 --> 00:09:03,379
THEY BRACE THE CONNECTORS TO
THE TUBES FOR A LEAKPROOF FIT.
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00:09:05,793 --> 00:09:09,724
THIS DUCTLESS AIR CONDITIONER
COIL IS NOW COMPLETE.
145
00:09:09,724 --> 00:09:12,586
THEY'RE READY TO TEST IT
FOR LEAKS.
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00:09:12,586 --> 00:09:15,862
A TECHNICIAN PUMPS
COMPRESSED AIR INTO THE UNIT
147
00:09:15,862 --> 00:09:17,620
TO SIMULATE REFRIGERANT.
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00:09:17,620 --> 00:09:20,517
BY USING COMPRESSED AIR,
THEY'RE PLAYING IT SAFE,
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00:09:20,517 --> 00:09:22,448
BECAUSE UNLIKE REFRIGERANT,
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00:09:22,448 --> 00:09:26,103
IT WON'T DAMAGE THE ENVIRONMENT
IF THEY'RE ACTUALLY IS A LEAK.
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00:09:26,103 --> 00:09:29,000
ONCE THE COIL IS FULL
OF COMPRESSED AIR,
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00:09:29,000 --> 00:09:32,103
HE IMMERSES THE PART IN WATER.
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00:09:32,103 --> 00:09:36,620
AIR BUBBLING OUT WOULD INDICATE
A LEAK THAT NEEDS FIXING.
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00:09:39,689 --> 00:09:42,344
A WORKER KEEPS A CLOSE WATCH
ON EACH COIL
155
00:09:42,344 --> 00:09:44,862
AS IT FLOATS BY
FOR SIGNS OF TROUBLE.
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00:09:47,103 --> 00:09:50,344
THEY'RE NOW READY TO ASSEMBLE
THE ENTIRE CONDENSER.
157
00:09:50,344 --> 00:09:53,689
THE TEAM SCREWS THE COMPRESSOR
TO THE BASE.
158
00:09:53,689 --> 00:09:55,413
THEY INSTALL THE COIL
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00:09:55,413 --> 00:09:58,655
AND ATTACH A MOTOR AND FANS
TO COOL THE REFRIGERANT.
160
00:10:02,655 --> 00:10:05,103
THE NEXT PART
IS THE FILTER DRYER.
161
00:10:05,103 --> 00:10:07,862
IT CONTAINS CHEMICALS
TO REMOVE MOISTURE
162
00:10:07,862 --> 00:10:09,793
AND FILTER OUT CONTAMINANTS.
163
00:10:09,793 --> 00:10:12,620
THEY INSTALL THE WIRING
AND CONTROL PANEL
164
00:10:12,620 --> 00:10:15,931
FOR THE COMPRESSOR
AND FAN MOTOR.
165
00:10:15,931 --> 00:10:18,689
THE TEAM CONNECTS THE PUMP
TO THE COIL
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00:10:18,689 --> 00:10:21,965
TO SUCTION OUT AIR
AND CREATE A VACUUM INSIDE,
167
00:10:21,965 --> 00:10:25,724
CREATING A PERFECT ENVIRONMENT
FOR THE REFRIGERANT GAS.
168
00:10:27,931 --> 00:10:29,931
HE CLOSES THE SERVICE VALVES
169
00:10:29,931 --> 00:10:33,068
AND SENDS THE DUCTLESS
AIR-CONDITIONING UNIT
170
00:10:33,068 --> 00:10:36,379
DOWN THE PRODUCTION LINE TO BE
CHARGED WITH REFRIGERANT.
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00:10:39,827 --> 00:10:42,000
AFTER THAT, ALL THAT'S LEFT
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00:10:42,000 --> 00:10:45,103
IS THE PACKAGING
AND THE INSTALLATION.
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00:10:46,896 --> 00:10:48,310
ON A HOT DAY,
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00:10:48,310 --> 00:10:52,103
ALL THE CONSUMER NEEDS TO DO
IS GRAB THE REMOTE CONTROL
175
00:10:52,103 --> 00:10:55,241
AND ACTIVATE
THE DUCTLESS AIR CONDITIONER
176
00:10:55,241 --> 00:10:56,689
FOR SOME COOL AIR.
177
00:11:10,103 --> 00:11:12,206
Narrator:
DEVELOPED IN THE 1960s,
178
00:11:12,206 --> 00:11:15,241
WINDOW FILM IS A PRODUCT
WITH TRANSPARENT BENEFITS.
179
00:11:15,241 --> 00:11:18,103
APPLIED TO THE WINDOWS
OF VEHICLES AND BUILDINGS,
180
00:11:18,103 --> 00:11:19,862
THIS TINTED FILM LETS LIGHT IN
181
00:11:19,862 --> 00:11:22,827
WHILE SHUTTING OUT SOME
OF THE SUN'S HARMFUL RAYS.
182
00:11:22,827 --> 00:11:25,379
AND DEPENDING ON THE DARKNESS
OF THE TINT,
183
00:11:25,379 --> 00:11:27,724
IT ALSO PROVIDES A MEASURE
OF PRIVACY.
184
00:11:30,655 --> 00:11:33,206
TINTED WINDOW FILM
ALLOWS DRIVERS
185
00:11:33,206 --> 00:11:35,931
TO SEE THINGS
IN A DIFFERENT LIGHT,
186
00:11:35,931 --> 00:11:38,482
ONE THAT CAN BE
A LOT LESS HARSH.
187
00:11:38,482 --> 00:11:41,517
NOT ONLY DOES THE TINTING
MEAN LESS SQUINTING,
188
00:11:41,517 --> 00:11:43,862
IT ALSO REDUCES
THE AMOUNT OF HEAT
189
00:11:43,862 --> 00:11:46,275
THAT PERMEATES
THE VEHICLE'S CABIN.
190
00:11:46,275 --> 00:11:51,586
THIS FILM WILL ALSO HOLD GLASS
TOGETHER IF IT SHATTERS.
191
00:11:51,586 --> 00:11:54,931
BECAUSE DARK TINTS CAN MAKE IT
HARD FOR THE DRIVER
192
00:11:54,931 --> 00:11:56,965
TO SEE THE ROAD OR TO BE SEEN,
193
00:11:56,965 --> 00:12:00,758
THE USE OF WINDOW FILM IS
REGULATED IN MANY JURISDICTIONS.
194
00:12:00,758 --> 00:12:03,448
THE LAWS VARY
DEPENDING ON THE REGION,
195
00:12:03,448 --> 00:12:06,344
SO THE FACTORY MAKES
DIFFERENT WINDOW FILMS
196
00:12:06,344 --> 00:12:08,689
FOR DIFFERENT MARKETS
AND APPLICATIONS.
197
00:12:10,896 --> 00:12:15,724
THERE ARE NUMEROUS FORMULATIONS
FOR THE TINTED COATINGS.
198
00:12:15,724 --> 00:12:18,344
IT ALL STARTS
WITH THE ACRYLIC ADHESIVE
199
00:12:18,344 --> 00:12:21,655
THAT WILL HOLD THE LAYERS
OF PLASTIC FILM TOGETHER.
200
00:12:21,655 --> 00:12:24,344
THE ADHESIVE WILL ALSO SERVE
AS THE BASE
201
00:12:24,344 --> 00:12:27,724
FOR THE TINT
AND OTHER ADDITIVES.
202
00:12:27,724 --> 00:12:31,137
THE TECHNICIAN THINS
THE ADHESIVE WITH SOLVENT,
203
00:12:31,137 --> 00:12:35,275
WHICH WILL MAKE IT EASIER TO
BLEND IN THE OTHER INGREDIENTS.
204
00:12:38,379 --> 00:12:41,137
THOSE INGREDIENTS
INCLUDE CHEMICALS
205
00:12:41,137 --> 00:12:43,310
TO ABSORB ULTRAVIOLET RAYS...
206
00:12:46,482 --> 00:12:50,344
...INITIATORS TO MAKE
THE MIX CURE FASTER...
207
00:12:50,344 --> 00:12:52,344
AND FINALLY THE COLORANT.
208
00:12:52,344 --> 00:12:55,310
IT'S CARBON-BASED,
AND AS A RESULT,
209
00:12:55,310 --> 00:12:58,517
IT'S HIGHLY SOLUBLE
AND DISPERSES WELL.
210
00:13:00,551 --> 00:13:03,517
ACHIEVING THE RIGHT SHADE
OF COLORANT
211
00:13:03,517 --> 00:13:05,448
IS TRULY AN EXACT SCIENCE,
212
00:13:05,448 --> 00:13:08,482
ONE THAT STARTED BEFOREHAND
IN THE LAB.
213
00:13:08,482 --> 00:13:11,448
A TECHNICIAN MIXED UP
TEST BATCHES
214
00:13:11,448 --> 00:13:15,413
COMBINING ONE OR MORE DYES
WITH THE ADHESIVE BASE
215
00:13:15,413 --> 00:13:18,310
UNTIL SATISFIED
WITH THE RESULTS.
216
00:13:18,310 --> 00:13:21,137
ONCE THE ADHESIVE
HAS BEEN MIXED,
217
00:13:21,137 --> 00:13:24,620
THEY ADD A CHEMICAL CATALYST
TO ACTIVATE IT.
218
00:13:24,620 --> 00:13:27,206
THEY'RE NOW READY
FOR THE PLASTIC FILM.
219
00:13:27,206 --> 00:13:29,965
THERE ARE VARIOUS GRADES
AND THICKNESSES.
220
00:13:29,965 --> 00:13:32,241
THE TYPE USED
DEPENDS ON THE TYPE
221
00:13:32,241 --> 00:13:34,586
OF WINDOW FILM
BEING MANUFACTURED.
222
00:13:34,586 --> 00:13:37,758
THE PLASTIC FILM
UNWINDS OVER ROLLERS
223
00:13:37,758 --> 00:13:39,827
INTO THE COATING MACHINE.
224
00:13:39,827 --> 00:13:41,241
AT THE SAME TIME,
225
00:13:41,241 --> 00:13:44,965
THE TINTED ADHESIVE FLOWS
INTO A PAN IN THE MACHINE.
226
00:13:44,965 --> 00:13:49,241
A ROLLER SOAKS UP THE ADHESIVE
AND APPLIES IT TO THE PLASTIC.
227
00:13:49,241 --> 00:13:52,275
THE COATED FILM TRAVELS
OVER A NARROW CYLINDER
228
00:13:52,275 --> 00:13:54,275
WITH FINE GROOVES
ETCHED INTO IT,
229
00:13:54,275 --> 00:13:57,310
AND THE EXCESS FORMULATION
COLLECTS IN THE GROOVES
230
00:13:57,310 --> 00:13:59,724
AND DRIPS BACK INTO THE TANK.
231
00:13:59,724 --> 00:14:04,482
THIS GETS RID OF THE EXCESS
AND ENSURES AN EVEN APPLICATION.
232
00:14:04,482 --> 00:14:07,724
THE FILM THEN MOVES
THROUGH A LONG DRYER,
233
00:14:07,724 --> 00:14:10,896
AND THE HEAT CAUSES
THE COATING TO CURE.
234
00:14:13,724 --> 00:14:17,241
THE FILM EXITS UNDER A GLARE
OF BLUE U.V. LIGHT.
235
00:14:17,241 --> 00:14:20,275
THE LIGHT ACTIVATES
THE INITIATOR CHEMICALS
236
00:14:20,275 --> 00:14:23,206
IN THE ADHESIVE
TO FURTHER CURE THE COATING.
237
00:14:23,206 --> 00:14:25,793
NEXT, A SECOND
PLASTIC FILM UNWINDS
238
00:14:25,793 --> 00:14:28,275
AND MEETS UP
WITH THE COATED ONE.
239
00:14:28,275 --> 00:14:32,068
THEY TRAVEL BETWEEN ROLLERS
THAT APPLY HEAT AND PRESSURE
240
00:14:32,068 --> 00:14:34,655
TO LAMINATE
THE TWO FILMS TOGETHER.
241
00:14:34,655 --> 00:14:37,586
A COMPUTERIZED SYSTEM
CHECKS FOR DEFECTS,
242
00:14:37,586 --> 00:14:39,758
AND A WORKER DOES A DOUBLE CHECK
243
00:14:39,758 --> 00:14:43,275
AS THE FILM PASSES IN FRONT
OF A BRIGHT LIGHT.
244
00:14:43,275 --> 00:14:45,689
AFTER A THIRD FILM,
MOUNTING ADHESIVE,
245
00:14:45,689 --> 00:14:48,758
AND RELEASE LINER HAVE BEEN
APPLIED TO THE PRODUCT,
246
00:14:48,758 --> 00:14:50,724
A TECHNICIAN TESTS A SAMPLE.
247
00:14:50,724 --> 00:14:53,310
SHE PULLS IT OFF
A PIECE OF GLASS,
248
00:14:53,310 --> 00:14:56,931
AND A SENSOR MEASURES THE AMOUNT
OF FORCE IT TAKES.
249
00:14:56,931 --> 00:15:01,172
THE TEST CONFIRMS THE WINDOW
FILM GRIPS THE GLASS ADEQUATELY.
250
00:15:01,172 --> 00:15:04,241
THE PRODUCTION RUN
GETS THE GREEN LIGHT,
251
00:15:04,241 --> 00:15:07,172
SO NEXT BLADES TRIM THE SIDES
AND CUT IT TO WIDTH.
252
00:15:09,758 --> 00:15:13,689
THE WIDTH OF THE FILM
CAN BE CUSTOMIZED TO THE JOB.
253
00:15:16,379 --> 00:15:18,758
AT THE END OF THE CUTTING LINE,
254
00:15:18,758 --> 00:15:23,000
A WORKER SLIDES A PLASTIC CORE
ONTO A CYLINDER.
255
00:15:23,000 --> 00:15:28,379
HE STICKS THE END OF THE WINDOW
FILM ONTO THAT CORE.
256
00:15:31,068 --> 00:15:34,793
HE ACTIVATES THE CYLINDER,
AND IT REVOLVES
257
00:15:34,793 --> 00:15:37,931
TO WIND THE FILM UP
ONTO THE CORE.
258
00:15:37,931 --> 00:15:39,206
SOLD IN ROLLS,
259
00:15:39,206 --> 00:15:42,655
THE FILM WILL LATER BE CUT
FOR AN EXACT FIT
260
00:15:42,655 --> 00:15:45,586
TO VARIOUS WINDOWS
BY AN INSTALLER.
261
00:15:47,206 --> 00:15:50,413
WINDOW FILM COMES
IN A RANGE OF COLORS
262
00:15:50,413 --> 00:15:53,310
WITH A VARIETY
OF CHARACTERISTICS.
263
00:15:53,310 --> 00:15:57,137
THE CHOICE IS UP
TO THE CUSTOMER.
264
00:15:57,137 --> 00:15:59,068
BUT NO MATTER WHAT,
265
00:15:59,068 --> 00:16:03,793
WINDOW FILM IS SURE TO CHANGE
ONE'S VIEW OF THINGS.
266
00:16:17,724 --> 00:16:19,103
Narrator: MOTORCYCLE RACERS
267
00:16:19,103 --> 00:16:21,000
TYPICALLY REPLACE THEIR BIKE'S
STANDARD EXHAUST SYSTEM
268
00:16:21,000 --> 00:16:22,137
WITH A HIGH-PERFORMANCE ONE,
269
00:16:22,137 --> 00:16:24,413
WHICH EMITS
EXHAUST GASES FASTER,
270
00:16:24,413 --> 00:16:26,896
CLEARING THE WAY
FOR NEW FUEL AND AIR
271
00:16:26,896 --> 00:16:29,586
TO ENTER THE ENGINE'S
COMBUSTION CHAMBER,
272
00:16:29,586 --> 00:16:32,344
GENERATING MORE POWER
AND BETTER TRACTION,
273
00:16:32,344 --> 00:16:35,310
WHICH PRODUCES GREATER SPEED
ON THE RACETRACK.
274
00:16:37,068 --> 00:16:40,448
THIS HIGH-PERFORMANCE,
AFTERMARKET EXHAUST SYSTEM
275
00:16:40,448 --> 00:16:44,000
ISN'T ANY LOUDER THAN YOUR
STANDARD EXHAUST SYSTEM,
276
00:16:44,000 --> 00:16:46,620
YET IT DELIVERS
UP TO 30% MORE POWER
277
00:16:46,620 --> 00:16:49,068
DUE TO ITS MORE
EFFICIENT DESIGN.
278
00:16:49,068 --> 00:16:51,379
RATHER THAN STEEL CONSTRUCTION,
279
00:16:51,379 --> 00:16:53,793
IT'S MADE PRIMARILY OF TITANIUM,
280
00:16:53,793 --> 00:16:57,310
WHICH IS MORE DURABLE
AND WEIGHS HALF AS MUCH.
281
00:16:57,310 --> 00:17:00,310
THE EXHAUST SYSTEM
HAS TWO MAIN COMPONENTS --
282
00:17:00,310 --> 00:17:02,655
THE MUFFLER,
WHICH DAMPENS SOUND,
283
00:17:02,655 --> 00:17:04,137
AND THE HEADER,
284
00:17:04,137 --> 00:17:07,517
WHICH ROUTES EXHAUST GASES
FROM THE ENGINE TO THE MUFFLER.
285
00:17:07,517 --> 00:17:11,827
THE HEADER'S TUBING IS MADE FROM
A SUPER-THIN STRIP OF TITANIUM
286
00:17:11,827 --> 00:17:13,551
THAT'S SIX INCHES WIDE.
287
00:17:13,551 --> 00:17:16,586
IT ENTERS A FORMING MACHINE,
288
00:17:16,586 --> 00:17:20,137
IN WHICH 14 STATIONS OF ROLLERS
APPLY TONS OF PRESSURE
289
00:17:20,137 --> 00:17:24,344
TO PROGRESSIVELY CURVE THE EDGE
OF THE STRIP UPWARD
290
00:17:24,344 --> 00:17:26,620
UNTIL THEY MEET AT THE TOP.
291
00:17:32,275 --> 00:17:35,965
THE FORMED TUBE,
TWO INCHES IN DIAMETER,
292
00:17:35,965 --> 00:17:38,000
THEN ENTERS A CHAMBER.
293
00:17:38,000 --> 00:17:40,310
INSIDE, A WELDER HEATS THE TOP
294
00:17:40,310 --> 00:17:44,068
UNTIL THE EDGES FUSE TOGETHER
INTO A SOLID SEAM.
295
00:17:44,068 --> 00:17:49,586
AFTER THE 330-YARD-LONG TUBE
EXITS THE WELDING CHAMBER,
296
00:17:49,586 --> 00:17:51,931
A POWERFUL, CARBIDE
GUILLOTINE BLADE
297
00:17:51,931 --> 00:17:54,241
CHOPS IT INTO SEVERAL
SHORTER TUBES.
298
00:17:56,137 --> 00:17:58,655
THEN, WORKERS MOUNT
EACH OF THOSE SHORTER TUBES
299
00:17:58,655 --> 00:18:00,275
ONTO A COMPUTER-GUIDED MACHINE,
300
00:18:00,275 --> 00:18:03,000
WHICH BENDS IT
TO THE SHAPE REQUIRED
301
00:18:03,000 --> 00:18:05,000
FOR SEVERAL EXHAUST SYSTEMS.
302
00:18:13,000 --> 00:18:16,344
WORKERS THEN SEPARATE
EACH SYSTEM'S TUBING
303
00:18:16,344 --> 00:18:18,000
WITH A CIRCULAR SAW.
304
00:18:18,000 --> 00:18:22,275
LIKE THE GUILLOTINE BEFORE,
THE SAW HAS A CARBIDE BLADE.
305
00:18:22,275 --> 00:18:24,896
AN ORDINARY STEEL BLADE
ISN'T HARD ENOUGH
306
00:18:24,896 --> 00:18:27,482
TO SAW THROUGH TITANIUM.
307
00:18:27,482 --> 00:18:31,000
A WELDER ASSEMBLES THE TUBES
TO THE OTHER HEADER COMPONENTS,
308
00:18:31,000 --> 00:18:33,724
AMONG THEM THE COLLAR
AND FLANGE,
309
00:18:33,724 --> 00:18:36,827
WHICH CONNECT THE HEADER
TO THE ENGINE...
310
00:18:36,827 --> 00:18:39,517
AND THE BULBOUS
RESONANCE CHAMBER,
311
00:18:39,517 --> 00:18:41,206
ALSO MADE OF TITANIUM.
312
00:18:41,206 --> 00:18:44,137
IT DOES A PRE-MUFFLER
SOUND DAMPENING.
313
00:18:44,137 --> 00:18:47,931
ONCE THE PARTS ARE WELDED
AND INSPECTED,
314
00:18:47,931 --> 00:18:50,103
THE HEADER IS FINISHED.
315
00:18:50,103 --> 00:18:52,413
THEY BEGIN ASSEMBLING
THE MUFFLER
316
00:18:52,413 --> 00:18:55,689
BY JOINING THE TWO HALVES
OF ITS RESONANCE CHAMBER.
317
00:18:55,689 --> 00:18:58,137
THE PARTS MUST FIT
WITH A TIGHT SEAL
318
00:18:58,137 --> 00:19:01,379
TO PREVENT EXHAUST GASES
FROM LEAKING OUT.
319
00:19:04,931 --> 00:19:08,655
THEY SET THE RESONANCE CHAMBER
ON A WELDING FIXTURE,
320
00:19:08,655 --> 00:19:11,793
TAKE A RING MADE
OF PERFORATED TITANIUM,
321
00:19:11,793 --> 00:19:14,586
AND WELD IT
TO THE CHAMBER OPENING.
322
00:19:14,586 --> 00:19:18,034
THIS RING ALLOWS
A SPECIFIC AMOUNT OF GASES
323
00:19:18,034 --> 00:19:20,620
TO ENTER THE RESONANCE CHAMBER
AT A TIME.
324
00:19:20,620 --> 00:19:23,344
NEXT, THEY WELD
A SOUND-ABSORPTION TUBE
325
00:19:23,344 --> 00:19:26,103
TO THE RESONANCE CHAMBER.
326
00:19:26,103 --> 00:19:28,620
THEY WRAP
THE SOUND-ABSORPTION TUBE
327
00:19:28,620 --> 00:19:30,310
IN A FIBERGLASS BLANKET.
328
00:19:32,310 --> 00:19:35,137
THE MUFFLER'S HOUSING IS MADE
OF A TITANIUM SHEET
329
00:19:35,137 --> 00:19:37,551
WHICH A MACHINE SHAPES
INTO A CANNISTER.
330
00:19:40,551 --> 00:19:42,448
AT EACH EDGE,
331
00:19:42,448 --> 00:19:43,551
THEY PEEL BACK THE FILM
332
00:19:43,551 --> 00:19:45,413
PROTECTING THE SURFACE
FROM SCRATCHES,
333
00:19:45,413 --> 00:19:47,620
THEN, WITH AN AUTOMATED WELDER,
334
00:19:47,620 --> 00:19:50,241
JOIN THE EDGES
WITH A STRONG SEAM.
335
00:20:02,965 --> 00:20:05,931
THEN THEY REMOVE
THE PROTECTIVE FILM ENTIRELY
336
00:20:05,931 --> 00:20:08,448
AND ELECTRICALLY CHARGE
THE CANNISTER
337
00:20:08,448 --> 00:20:11,551
IN A MILD CHEMICAL SOLUTION
FOR ABOUT A MINUTE.
338
00:20:11,551 --> 00:20:13,620
THIS ANODIZING, AS IT'S CALLED,
339
00:20:13,620 --> 00:20:16,068
CHANGES THE COLOR
OF THE TITANIUM
340
00:20:16,068 --> 00:20:19,344
AND HARDENS THE SURFACE,
MAKING IT MORE DURABLE.
341
00:20:19,344 --> 00:20:22,310
AFTER ATTACHING AN ALUMINUM
MOUNTING BRACKET
342
00:20:22,310 --> 00:20:23,551
TO THE CANNISTER,
343
00:20:23,551 --> 00:20:26,172
THEY INSERT
THE SOUND-ABSORPTION TUBE,
344
00:20:26,172 --> 00:20:30,034
THEN SECURE THE CANNISTER
TO THE RESONANCE CHAMBER
345
00:20:30,034 --> 00:20:31,103
WITH SCREWS.
346
00:20:35,413 --> 00:20:37,965
THEY APPLY
THE MANUFACTURER'S STICKER,
347
00:20:37,965 --> 00:20:41,551
AND THE MUFFLER PORTION OF
THE EXHAUST SYSTEM IS FINISHED.
348
00:20:46,310 --> 00:20:48,241
TO INSTALL THE EXHAUST SYSTEM,
349
00:20:48,241 --> 00:20:50,586
YOU BOLT THE HEADER
TO THE MOTOR,
350
00:20:50,586 --> 00:20:53,517
WHICH IS TOWARD THE FRONT
OF THE MOTORCYCLE,
351
00:20:53,517 --> 00:20:56,482
THEN MOUNT THE MUFFLER TO
THE OTHER END OF THE HEADER.
352
00:20:58,206 --> 00:21:00,482
THE MUFFLER BOLTS
TO THE BIKE CHASSIS
353
00:21:00,482 --> 00:21:02,344
VIA A BRACKET ON THE CANNISTER.
354
00:21:04,275 --> 00:21:07,965
NOW THE BIKE IS READY
TO HIT THE RACETRACK.
355
00:21:14,862 --> 00:21:17,862
--Captions by VITAC--
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356
00:21:17,862 --> 00:21:21,586
CAPTIONS PAID FOR BY
DISCOVERY COMMUNICATIONS
357
00:21:21,586 --> 00:21:24,103
IF YOU HAVE ANY COMMENTS
ABOUT THE SHOW,
358
00:21:24,103 --> 00:21:26,724
OR IF YOU'D LIKE TO SUGGEST
TOPICS FOR FUTURE SHOWS,
359
00:21:26,724 --> 00:21:28,862
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