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--captions by vitac--
Www.Vitac.Com
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Captions paid for by
Discovery communications, inc.
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Narrator:
Today on "How it's made"...
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Hearing aids.
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Narrator: we're turning up
The volume for this one.
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3-d puzzles --
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A traditional pastime
Enters a new dimension.
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Rubber mats --
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We bring you
A step-by-step explanation.
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00:00:43,379 --> 00:00:45,103
And toilets --
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00:00:45,103 --> 00:00:48,793
This fascinating report
Leaves us flushed with pride.
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When you stop and listen
To all the sounds around you,
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You suddenly realize
How easy it is
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To take your hearing
For granted.
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00:01:01,586 --> 00:01:04,275
If you ever develop
A hearing disorder,
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You'll undoubtedly
Feel the loss.
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Thankfully, though,
Hearing aids are tinier
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And more effective
Than ever before.
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Loss of hearing
Causes a serious handicap,
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But, happily, it can be remedied
Thanks to hearing aids.
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But before fabricating the aid,
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The degree of hearing loss
Must be precisely measured
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With this apparatus
Called an audiometer.
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So they make a mold
Of the ear canal.
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To protect the eardrum,
An autoblock is inserted.
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00:01:37,275 --> 00:01:38,965
The next step is to pour in
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A silicon
Impression-making material.
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It solidifies and is then
Removed from the ear.
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00:01:49,448 --> 00:01:52,103
This congealed mass
Representing the ear canal
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00:01:52,103 --> 00:01:56,551
Is then soaked in warm wax
To obtain a positive imprint.
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Then the silicon container
Is filled.
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The silicon hardens
In only 10 minutes.
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The hardened silicon block
Is removed,
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00:02:16,137 --> 00:02:18,793
And the excess of the imprint
Is trimmed away
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So that only the essential part
Is retained.
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The imprint must slip easily
Into the ear.
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It's now the molding stage
For the hearing aid.
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Acrylic is poured into the mold
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00:02:29,620 --> 00:02:32,793
Before placing it
Into this ultraviolet oven.
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Without emitting any heat,
This oven hardens the acrylic.
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Here is the raw prosthesis
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Without its electronic
Components.
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This plan details the electric
Circuit of the amplifier.
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Holes are pierced
For the volume control.
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These components are tiny.
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00:02:52,586 --> 00:02:54,724
Here is the volume control...
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...The miniature microphone
That captures sounds...
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00:03:01,068 --> 00:03:05,482
And the earphone,
Which functions as a speaker.
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00:03:05,482 --> 00:03:08,965
This tiny braided wire
Of seven conductors
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Is soldered to the amplifier
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00:03:10,620 --> 00:03:13,172
And other parts
Of the prosthesis with pewter.
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00:03:16,103 --> 00:03:18,931
The hybrid circuit is inserted
Into a silicon casing,
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Which assures its protection.
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Then the wires are soldered
To the speaker.
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And they verify
The proper functioning
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Of the volume control.
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A hearing aid
Must be very discreet.
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That's why they cut the excess
With a diamond disk.
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They also remove the roughness
With fine sandpaper.
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The holes we see here are used
To vent air from the earphone.
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This silicone tube
Is used to make the vent.
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Acrylic is poured onto the tube
To form a tunnel.
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00:03:57,241 --> 00:04:02,206
Ultraviolet light is used
To harden the acrylic.
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Afterwards, the tube is removed.
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This hole is used
To position the fastener,
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A small wire which allows
For removing the hearing aid
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From the ear.
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Then the battery is installed.
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00:04:22,068 --> 00:04:24,551
Only a few parts,
Such as the microphone,
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00:04:24,551 --> 00:04:26,965
Remain to be put in place.
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Then everything
Is delicately assembled
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Into the interior
Of the prosthesis.
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The two parts of the hearing aid
Are then glued together.
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00:04:40,482 --> 00:04:42,931
Ultraviolet hardens the glue.
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The plate used to position
The prosthesis components
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Is cut away with the drill.
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Then the hearing aid
Is manually polished
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00:04:53,931 --> 00:04:56,862
To make it perfectly smooth
And comfortable.
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The prosthesis is now completed.
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There remains
One important step --
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Verifying its electroacoustic
Characteristic.
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It's with this analyzer
That they validate
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That the hearing aid conforms
To the original prescription.
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These minute prostheses
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Allow us to solve
The main hearing problems.
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Microfabrication
Of a single unit
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Requires a little more
Than two days of work.
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Narrator: remember spending
Lazy afternoons
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Putting together simple
60-piece jigsaw puzzles?
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Well, put that image
Out of your mind,
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00:05:58,827 --> 00:06:01,448
Because today's
Sophisticated puzzles
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00:06:01,448 --> 00:06:04,034
Can have 1,500 3-d pieces
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That go up, down,
And even sideways.
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00:06:07,965 --> 00:06:09,931
Are you up for the challenge?
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00:06:14,172 --> 00:06:16,620
Flat puzzles are well known
By everyone,
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00:06:16,620 --> 00:06:19,655
But 3-d puzzles present
A different challenge.
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00:06:19,655 --> 00:06:21,931
These 3-dimensional puzzles
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00:06:21,931 --> 00:06:24,965
Are first conceived
With computer software.
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Good blades are needed
To cut puzzle pieces.
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Here are the blades
For the master die
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Which will cut out printed
Sheets of different models.
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This rubber will be used
To eject the die.
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The master cutting die
Is unique to each puzzle.
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It is the specific pattern
Used to make the puzzle.
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00:06:57,620 --> 00:07:01,965
They measure it meticulously
To obtain a perfect register.
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00:07:01,965 --> 00:07:05,862
It's imperative that the die
Not move during the cutting,
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00:07:05,862 --> 00:07:08,689
Otherwise the pieces would be
Cut at the wrong points,
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00:07:08,689 --> 00:07:12,310
So they very firmly
Secure it in place.
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00:07:27,724 --> 00:07:30,103
The carbon of the die
Is positioned.
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It's somewhat like
Printing the master.
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Alignment is again verified,
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A highly important step
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00:07:36,034 --> 00:07:39,310
Which assures the quality
Of the final product.
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Finally, they install
This large metallic plate,
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Which is the cutting base.
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It will be on this surface
That the master die will strike.
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Once measurements are finished,
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The drawer of the die
Is slid into place.
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00:08:02,551 --> 00:08:05,862
This press cuts the pattern
Seen on the puzzle.
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00:08:05,862 --> 00:08:07,620
Here's how it works.
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00:08:07,620 --> 00:08:09,275
The sheets,
Or printed cardboards,
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Go into the drawer one by one,
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00:08:12,103 --> 00:08:14,137
Where they are cut according
To the master model.
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00:08:20,413 --> 00:08:24,793
We clearly see the press making
The cut in the puzzle sheet.
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00:08:28,793 --> 00:08:32,034
The cut sheets
Pile up on one another.
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00:08:35,896 --> 00:08:39,827
At this checkpoint, they verify
The precision of the cut.
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00:08:39,827 --> 00:08:43,413
They make sure that every piece
Is correctly shaped.
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00:08:47,344 --> 00:08:50,448
Now they go to the foam support
Of the puzzle.
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00:08:50,448 --> 00:08:54,103
This guillotine is used
To cut the polyethylene sheets
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00:08:54,103 --> 00:08:57,586
Onto which they will glue
The cut images.
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Foam sheets are inserted
Into this laminator
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Heated to 450 degrees.
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00:09:08,344 --> 00:09:11,655
The sheet with the design on it
Is glued onto the foam
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00:09:11,655 --> 00:09:15,034
With a thermosetting adhesive.
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00:09:15,034 --> 00:09:18,448
Now they glue the printed sheet
Onto the foam sheet.
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Once the adhesion is finished,
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00:09:25,965 --> 00:09:28,551
The puzzles are stacked
On one another,
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00:09:28,551 --> 00:09:30,827
And they proceed
To the unbuckling operation.
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00:09:30,827 --> 00:09:34,517
By pulling, they remove
The surplus cuttings.
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00:09:39,793 --> 00:09:43,758
The same design is printed
Several times on a sheet,
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00:09:43,758 --> 00:09:45,931
So they must separate
Each puzzle.
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00:09:45,931 --> 00:09:49,344
This step is called
The reduction of the models.
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00:09:55,137 --> 00:09:57,896
Now the pieces
Have to be separated.
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00:09:57,896 --> 00:10:00,103
This decorticator
Handles this task
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00:10:00,103 --> 00:10:02,724
And sends the pieces
Down a chute.
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00:10:09,068 --> 00:10:11,724
Packing cartons arrive
Already made up,
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00:10:11,724 --> 00:10:14,862
And the puzzle pieces
Are placed in their boxes.
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00:10:14,862 --> 00:10:19,241
No less than 15,000 puzzles
Are produced here each day.
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00:10:19,241 --> 00:10:21,206
Since it began operations,
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00:10:21,206 --> 00:10:24,448
The company has created more
Than 300 different puzzle models
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00:10:24,448 --> 00:10:28,517
From quite simple ones
To much more complex designs.
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00:10:28,517 --> 00:10:30,620
The largest of them
Contain a total
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00:10:30,620 --> 00:10:35,103
Of more than 3,000 pieces.
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00:10:35,103 --> 00:10:38,344
And you need real patience
For this one.
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Narrator:
Ever wonder what happens
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00:10:49,103 --> 00:10:52,103
To the millions of used tires
We throw out every year?
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00:10:52,103 --> 00:10:53,931
Well, you'll be relieved to know
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00:10:53,931 --> 00:10:57,068
That burning tires
Is a thing of the past.
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Today's tires are often given
New life as rubber mats.
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Some are even big enough
To cover whole arenas.
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Now, that's recycling.
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00:11:15,068 --> 00:11:18,172
Used tires are a real source
Of pollution.
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00:11:18,172 --> 00:11:21,172
This pile represents
About 100,000 of them.
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00:11:21,172 --> 00:11:24,103
At any rate, these tires
Will have a second life.
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They'll be recycled
To make rubber mats.
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00:11:26,620 --> 00:11:28,275
Each day in this factory,
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00:11:28,275 --> 00:11:31,965
They recycle 15,000 tires
Into mats.
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00:11:31,965 --> 00:11:35,034
Tires have to be reduced
To little granules,
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00:11:35,034 --> 00:11:38,724
But first this conveyor feeds
The tires into the washer.
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00:11:38,724 --> 00:11:39,965
Tires are washed
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00:11:39,965 --> 00:11:42,758
With a water-based
Biodegradable preparation.
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00:11:42,758 --> 00:11:44,241
Then they're sent
To the shredder.
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00:11:46,896 --> 00:11:49,379
The shredder has two rows
Of large teeth.
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00:11:49,379 --> 00:11:52,310
These grind up the tires
Into pieces.
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00:11:58,000 --> 00:12:02,310
This shredder is able to cut up
Almost 1,000 tires an hour.
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They come out as fairly
Good-sized pieces of tires,
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00:12:05,310 --> 00:12:07,724
Which are then shredded
A second time.
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Metal is magnetically separated
From the rubber,
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00:12:16,482 --> 00:12:19,931
And the metal pieces
Are recycled at another factory.
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00:12:25,448 --> 00:12:28,724
Other components of the tires,
Such as fiberglass and nylon,
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00:12:28,724 --> 00:12:30,724
Also have to be separated.
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They use a sifter to get out
Unwanted rubbish.
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Recuperated rubber particles
Purged of foreign materials
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00:12:39,965 --> 00:12:42,586
Measure about 1/10 of an inch.
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00:12:42,586 --> 00:12:45,275
Some 16 tons of tire particles
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00:12:45,275 --> 00:12:48,137
Are piled up
In this recycling depot.
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00:12:51,758 --> 00:12:54,931
But the particles are still
Too large to be used.
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00:12:54,931 --> 00:12:57,965
They're sent to a secondary
Shredder supply tank,
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00:12:57,965 --> 00:13:00,586
Where they'll be reduced
Even further.
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00:13:04,172 --> 00:13:07,034
This tractor feeds
The secondary shredder.
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00:13:07,034 --> 00:13:10,172
Grinding action produces
A kind of rubber powder.
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00:13:16,517 --> 00:13:21,620
The powder is spread out
On these enormous molds.
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00:13:21,620 --> 00:13:23,931
This mold has a length
Of 23 feet
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00:13:23,931 --> 00:13:25,620
And a width of 4 feet.
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00:13:25,620 --> 00:13:28,965
Thickness varies according
To the product being made.
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00:13:28,965 --> 00:13:31,034
The molds filled
With rubber powder
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00:13:31,034 --> 00:13:33,689
Are stored in this loading
Magazine of the press.
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00:13:33,689 --> 00:13:37,517
Once full, the molds are sent
To the rubber-mat press.
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00:13:40,965 --> 00:13:43,068
Here's the mat press.
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00:13:43,068 --> 00:13:45,931
The powder has to be cooked
At a very high temperature
201
00:13:45,931 --> 00:13:47,620
For about 30 minutes.
202
00:13:47,620 --> 00:13:50,517
Cooking time depends
On the product being made.
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00:13:52,310 --> 00:13:54,965
The cooked mat goes
To the unmolding unit
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00:13:54,965 --> 00:13:57,137
Before being sent off to cool.
205
00:13:58,862 --> 00:14:01,896
The rubber mats
Are still extremely hot.
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00:14:01,896 --> 00:14:04,000
They're cooled
With jets of water
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00:14:04,000 --> 00:14:05,862
For a period of several minutes.
208
00:14:13,482 --> 00:14:18,068
The cooled mats can now be sent
To the next department.
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00:14:18,068 --> 00:14:19,724
This conveyor
In the cutting center
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00:14:19,724 --> 00:14:21,827
Positions the mat
Before it's cut.
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00:14:21,827 --> 00:14:25,620
The mat is vibrated
To eliminate any surplus water.
212
00:14:30,551 --> 00:14:33,965
Each rubber mat is now cut up
Into three pieces.
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00:14:40,586 --> 00:14:43,310
The cut mats are then
Stacked into a pile
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00:14:43,310 --> 00:14:45,620
And stored before being shipped.
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00:14:52,793 --> 00:14:55,241
The company
Also makes mudguards.
216
00:14:55,241 --> 00:14:58,896
These are fabricated the same
Way as the preceding mats.
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00:14:58,896 --> 00:15:01,000
After having been cooled
In water,
218
00:15:01,000 --> 00:15:04,241
But while they're still warm,
They remove the surplus rubber.
219
00:15:04,241 --> 00:15:07,000
This operation
Is called "Notching."
220
00:15:13,793 --> 00:15:17,655
Hard rubber rings are also
Produced at this facility
221
00:15:17,655 --> 00:15:19,517
With the same
Fabrication methods
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00:15:19,517 --> 00:15:23,000
And, as always,
From old, used tires.
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00:15:23,000 --> 00:15:24,896
Over a 12-hour period,
224
00:15:24,896 --> 00:15:28,413
This facility makes no less
Than 12,000 rubber mats
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00:15:28,413 --> 00:15:30,758
From old, recycled tires.
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00:15:30,758 --> 00:15:34,965
This translates into good news
For our environment.
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00:15:44,793 --> 00:15:47,206
Narrator:
We tend not to put much thought
228
00:15:47,206 --> 00:15:50,068
Into this humblest
Of household appliances
229
00:15:50,068 --> 00:15:53,068
As long as it keeps doing
What it was built to do.
230
00:15:53,068 --> 00:15:55,448
But like most of the machines
We've invented
231
00:15:55,448 --> 00:15:57,068
To do our dirty work,
232
00:15:57,068 --> 00:15:58,724
We may take it for granted,
233
00:15:58,724 --> 00:16:03,379
But it's next to impossible to
Imagine life without the toilet.
234
00:16:10,758 --> 00:16:14,034
The first public restrooms
Appeared in ancient rome
235
00:16:14,034 --> 00:16:17,344
When the emperor vespasian
Built latrines.
236
00:16:17,344 --> 00:16:18,931
Such public urinals
237
00:16:18,931 --> 00:16:23,620
Became widely known
As vespasiennes by 1840.
238
00:16:23,620 --> 00:16:28,172
In 1775, the invention
Of a water-flush system
239
00:16:28,172 --> 00:16:32,068
Created toilets somewhat
Resembling today's convenience.
240
00:16:32,068 --> 00:16:35,482
The valve and siphon
Were added in 1784
241
00:16:35,482 --> 00:16:38,413
And the septic tank in 1896.
242
00:16:46,758 --> 00:16:49,137
A toilet is an everyday object
243
00:16:49,137 --> 00:16:52,310
Whose fabrication requires
Several days of work.
244
00:16:52,310 --> 00:16:56,068
It involves assembling
Several molds called "Tools."
245
00:16:56,068 --> 00:17:00,413
Each new product requires the
Design of a master plaster mold
246
00:17:00,413 --> 00:17:03,586
From which they will produce
A plastic tool.
247
00:17:08,965 --> 00:17:11,827
This latter will be used
To create plaster duplicates
248
00:17:11,827 --> 00:17:14,551
Used as production molds.
249
00:17:19,103 --> 00:17:22,034
The plaster production mold
Of a toilet
250
00:17:22,034 --> 00:17:25,724
Is made from six different tools
Which have to be assembled.
251
00:17:25,724 --> 00:17:28,344
Their life-span
Is only two months.
252
00:17:28,344 --> 00:17:31,448
The process begins with
A mixture of water and plaster
253
00:17:31,448 --> 00:17:33,620
According to a precise recipe.
254
00:17:33,620 --> 00:17:37,482
Then the liquid is poured into
This filling hole of the tool.
255
00:17:37,482 --> 00:17:40,551
Once the plaster hardens,
They can proceed with unmolding.
256
00:17:40,551 --> 00:17:42,172
They strike the end
257
00:17:42,172 --> 00:17:44,689
At the junction
Of the plaster mold and the tool
258
00:17:44,689 --> 00:17:48,275
With a rubber hammer
So as not to damage the plaster.
259
00:17:56,689 --> 00:17:58,931
Pieces are gently assembled.
260
00:17:58,931 --> 00:18:01,517
The toilet softly
Takes its shape.
261
00:18:01,517 --> 00:18:05,586
It is in this same mold that
They will later color the clay.
262
00:18:11,896 --> 00:18:14,931
Then they install
Tensioning straps.
263
00:18:14,931 --> 00:18:18,103
Little blocks are inserted
Between the mold and the strap
264
00:18:18,103 --> 00:18:19,482
To increase the tension.
265
00:18:19,482 --> 00:18:21,827
The mold will soon be
Filled with liquid,
266
00:18:21,827 --> 00:18:24,724
And they thus prevent
Any distortion.
267
00:18:24,724 --> 00:18:26,586
Here a new recipe
Is being prepared.
268
00:18:26,586 --> 00:18:31,068
This time it's a slurry,
A composite of clay and silica.
269
00:18:31,068 --> 00:18:34,310
This preparation
Is spread out over 48 hours.
270
00:18:34,310 --> 00:18:37,862
Now they install the core,
The upper part of the mold.
271
00:18:37,862 --> 00:18:40,275
They can now proceed
With the filling.
272
00:18:41,896 --> 00:18:43,793
This copper distribution pipe
273
00:18:43,793 --> 00:18:45,965
Connected to the tank
Containing the slurry
274
00:18:45,965 --> 00:18:48,965
Permits the filling
Of several molds at a time.
275
00:18:48,965 --> 00:18:52,379
They need about 45 pounds
Of the mix per bowl mold.
276
00:18:55,034 --> 00:18:56,862
After an hour,
277
00:18:56,862 --> 00:19:00,482
The slurry has attained
A thickness of 4/10 of an inch.
278
00:19:00,482 --> 00:19:04,586
The plug is pulled to allow
The excess slurry to run out.
279
00:19:04,586 --> 00:19:07,931
They can now unmold
The still-fragile piece.
280
00:19:07,931 --> 00:19:09,896
This thicker slurry is used
281
00:19:09,896 --> 00:19:12,896
To adhere
These two pieces together.
282
00:19:23,172 --> 00:19:26,655
They cut the holes
And unmold the ensemble.
283
00:19:26,655 --> 00:19:29,275
The toilet is now molded.
284
00:19:32,517 --> 00:19:35,137
Then, to obtain
A perfect appearance,
285
00:19:35,137 --> 00:19:36,862
They remove the little fillet
286
00:19:36,862 --> 00:19:39,931
Formed by the surplus
Adhesive slurry.
287
00:19:43,586 --> 00:19:46,827
The toilets air-dry
For 36 hours,
288
00:19:46,827 --> 00:19:51,172
Then in a warm-air dryer
For 12 hours.
289
00:19:51,172 --> 00:19:53,379
Finishing must be impeccable.
290
00:19:53,379 --> 00:19:56,793
They carefully sand the surface
To make it perfectly smooth.
291
00:19:56,793 --> 00:19:59,689
A vacuum draws up the dust.
292
00:19:59,689 --> 00:20:02,586
Then, with a jet
Of compressed air,
293
00:20:02,586 --> 00:20:05,034
Dust and debris are blown away.
294
00:20:06,793 --> 00:20:10,034
Bowls are hand-painted
In a special room.
295
00:20:15,931 --> 00:20:17,379
As for the water tanks,
296
00:20:17,379 --> 00:20:19,862
They are painted
By an automated robot.
297
00:20:30,931 --> 00:20:32,965
This truck
Carries the different parts
298
00:20:32,965 --> 00:20:36,793
To the final
Fabrication stage -- baking.
299
00:20:38,448 --> 00:20:40,206
The toilets remain in this oven
300
00:20:40,206 --> 00:20:44,448
At the very high temperature
Of 2,150 degrees
301
00:20:44,448 --> 00:20:46,655
For 23 hours.
302
00:20:46,655 --> 00:20:49,586
It takes this long to fuse
The clay and silicone.
303
00:20:49,586 --> 00:20:52,413
The paint then becomes
Hard and shiny,
304
00:20:52,413 --> 00:20:54,413
And it's all done.
305
00:20:56,517 --> 00:20:58,862
The toilets
And the different bowls
306
00:20:58,862 --> 00:21:01,724
Now take on shapes more elegant
Than in the past,
307
00:21:01,724 --> 00:21:03,965
But the fabrication
Of each one of them
308
00:21:03,965 --> 00:21:06,413
Will have the same basic
Construction steps
309
00:21:06,413 --> 00:21:09,275
Involving 45 pounds of slurry
310
00:21:09,275 --> 00:21:11,965
And almost 4 days of labor.
311
00:21:17,275 --> 00:21:19,827
Narrator: if you have
Any comments about the show,
312
00:21:19,827 --> 00:21:22,448
Or if you'd like to suggest
Topics for future shows,
313
00:21:22,448 --> 00:21:25,137
Drop us a line at...
25327
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