I’ve spent the last sixty years complaining about getting kicked out of Carnegie Institute of Technology. It was the end of everything. When my Dad’s business went bankrupt, and he couldn’t pay second semester tuition and fees, it was all over for me. I convinced the Dean of Students to let me sign on personally to the debt in return for permission to take final exams. I sat for them, then packed my bags and took off for parts unknown.
In retrospect, losing my place in that very conservative engineering institution may have been the best thing ever to have happened to me. After recovering my stance as a viable though modest bread-winner, it was time to get back to school. Opportunities were limited. The only four-year possibility within Greyhound commuting distance was Salem, a West Virginia teacher’s college tucked into the green Appalachian foothills, between Parkersburg and Clarksburg. Engineering Physics wasn’t even offered. The closest thing to my one-time dream was Divisional Science, available to secondary level teachers of Biology, Chemistry and Physics. I signed on and didn’t look back.
Salem was a liberal arts college. That meant, I later discovered, that I would be exposed to a whole gamut of ideas, not just facts. There were many courses in a lively continuum of scientific subjects, but also with my minor in English, I enjoyed all the richness of our language spread out as a table of linguistic delights. For fun, there were spiritual electives, wherein I broadened my appreciation of what might be believed, how and why. French and Art fell by the wayside. I was sad to see them go, but you can’t learn everything. As I look back over the way that crazy-quilt of education overlaid the world of work, I see that Salem curriculum as key to becoming an inventor in a way that fulfilled my dream as well as my prayer. The dream was that I become an engineer my father could be proud of; the prayer was that he might love me even though I was a girl. One thing led to another, and three years later I packed it in with just one semester remaining, returning to Texas—home.
My work career started at Richardson’s TI in 1964 Dallas—showing up and demanding a job, any job. With two boys, 7 and 3, I had to get a life. Enough with an idealized West-Virginia-mountain-mama-home and crawling toward a degree. My kiddoes needed food and underpants. At Texas Instruments, Apparatus Division, I had plenty of opportunity to see things uniquely vantaged. Hired on as a lowly Assistant Assembler B, I soon reached back to the technical drawing learned at CIT and proposed a device to improve my workstation performance. An after-hours built wiring board design that provided for group measuring, cutting, stripping, and soldering got instant attention, a raise and a promotion. Then I got to write and illustrate assembly instructions until, repeatedly proposing work saving jigs and fixtures, I was promoted yet again to Tool Designer. At six weeks I was making thrce what I had at grunt start pay. TI was responsive. They didn’t sneer at good ideas. While there, carrying Badge Number 15695, I designed all the assembly tooling on the F-111 TFX program. That was exciting since the TFX (terrain following radar) was the program’s claim to fame. We were in the storm’s eye. All that was fun, but I had hit the ceiling. Even though I was assigned to coach every engineering school graduate new-hire how it was that I did what I did, no more money was possible without a college degree, and I was still one semester short of that achievement.
Transferring and crossing the street to TI’s Corporate Research and Engineering Division was a new start. It was a wonky place where they understood my frustration and let me work while earning a bit more money, even without the sheepskin. I worked for Dr. Linda Creagh who was doing research on 2-chloro-2-nitroso-butane, a photo reactive chemical, to demonstrate its use in working with a ruby laser as a research tool. This was chemistry—not physics. My job was to mix the required reagents to produce our compound, set up a distillation apparatus, and heat the slurry until it began boiling. As temperature elevated, different fractions evaporated, were condensed and caught. Each fraction was analyzed by a spectrophotometer to precisely measure its purity. The 2-chloro-2-nitroso-butane we were after was an azure blue fluid that when very pure could be exposed to laser light demonstrating a wide variety of amazements. But it wasn’t all that easy. No matter how much care I took in isolating a fraction, there always remained enough impurity to spoil its use inside the little glass photo cube that waited for us to get our act together.
I have often been amazed to find that the most innovative breakthroughs happen at the interstices of things. This was a chemical problem, but the solution I found was a physical one. We had been successful in producing very pure fractions of our chemical, but the impurities always seemed to be extremely volatile, evaporating at a very low temperature, and carried over into fractions where they didn’t belong. Remembering Halloweens spent over boiling kettles while wearing witches hats and croaking, ‘When shall we three meet again, in thunder, lightning, or in rain?’ I picked up a hunk of dry ice at the local ice house and brought it to work disguised as lunch.
I proposed my idea to Dr. Creagh, who listened with interest. We put a nearly pure fraction of 2-chloro-2-nitroso-butane into a beaker and dropped into it a small lump of the dry ice—frozen carbon dioxide. I counted on the dry ice not reacting to our compound, and the doctor agreed. No chemical interaction was expected. I was using the CO2 as an inert physical broom to brush away all those volatile impurities. It worked! The beaker frothed with CO2 being sublimed through the fluid—going direct from solid to gas and making a big froth—as the gas escaped, dragging volatile impurities up into the air and away. The project was saved, and when it was written up for publication, I had earned a footnote mention for my invention of “a method for removing volatile impurities from a fluid.” This was remarkable in that technicians don’t usually get any credit for anything, and for being one of many instances where innovation reaches across demarcations between specialties and fertilizes the process of invention.
This kind of approach served me well in a variety of situations. A typical example was working for Varo Inc. where I migrated a year later since that outfit allowed technicians to work flexible hours in order to accommodate illusive degree programs. I was a technician by day and attended advanced biochemistry classes at night. I was amazed at how many drums of flux remover that Varo bought and used, and at what great expense. So, I took some to school and analyzed it in the Chem Lab. It was mostly dry cleaning fluid, with a dollop of amyl acetate (an ester that makes bananas smell like banana). Varo started making its own flux remover and saving a bundle. This wasn’t a healthy or environmentally friendly idea since perchloroethylene isn’t something that should be continuously inhaled any more than Kester flux remover should be. But it was a mile-post on my march. It was also another shoulder rub from physical to chemical invention that earned me an ataboy—girl.
Yet another reach across as Engineer after I had acquired that elusive degree, was at Varo’s Static Power Division. It was a Sherman Texas facility devoted entirely to manufacture of night vision power supplies. Powering a night vision unit required a high voltage multiplier. It was a string of diodes cleverly arrayed to step up to the extremely high voltages needed to see in very low light. It was necessary to stabilize the component connections to prevent disastrous internal arcing. An obscenely expensive potting compound was used to achieve this electrical isolation. I replaced the compound with cheerfully cheap high tech beeswax. It worked just as well and saved Varo a ton of bucks. It could be melted and drained if necessary, and that was a big advantage.
Sometimes it isn’t even necessary to look for the bright idea light bulb. It’s just there glaring at you. My first day at the TI Sherman facility found me stepping over bulging garbage bags, bags on top of bags, bags of spacers spilling onto the floor, swept up by tricky breezes to dance away and hide. Of course the assembly line was stopped, quiet as death. The tried-and-true method had turned out to be a bust. Millions of plastic one-eighth inch diameter tiny plastic donuts stored in plastic bags were static discharge waiting to resolve. Every attempt to recapture the spacers and present them for automated assembly with their target diodes had failed—miserably. The charged spacers became a veritable fluid, had minds of their own, and resisted handling as they took flight willy-nilly inspired by their individual electromagnetic imperatives. My reputation as a wise-ass preceded me, and my first assignment was to “fix this mess.”
It seemed so obvious. The plastic spacers were formed in an injection molding machine inside a mold that formed twenty-four identical donuts, all tied together by the plastic caught in the molten plastic feed channels, called the sprue. The spacers already had the perfect holding fixture, needing only the foresight to use it. The sprue itself was every spacer’s perfect holder. The invention invented itself. I had only to design a tool that clamped the sprue with its twenty-four precisely located still-attached spacers while a human inserted twenty-four diodes into their yawning apertures, and only then pressed a button to automatically separate the twenty-four diode/spacer assemblies from the now superfluous sprue. It worked. The work-area was so tight that a single bar blade couldn’t access the washer/sprue attachment points, but twenty-four narrow gauge pointy tipped X-acto Knife Blades, cunningly mounted, did the trick. A solenoid provided the requisite actuation. An inclined plane allowed the blades to slide up and slice at just the right angle. Big red push-switches initiated first “clamp” and then “cut.” Making the switches dual-actuated kept fingers safely out-of-the-way. A single switch pressed did nothing; only when both right and left buttons were depressed would anything happen.
Years later at TRW while working on military aerospace proposals, it was often when experts in different specialties met and knocked heads that the creative work got done. My most satisfying personal contributions to those efforts seemed often rooted in that Salem College ambrosia of science as art. It was then that I decided getting booted out of Carnegie Tech was not all that bad. I’m told that this is one of the blessed truths of Kabballah: It’s where the wounds of life open you up that the light gets in and creates your beauty.
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