Abstract: Pattern for the lost foam casting process including a pouring-basin-foming portion, a sprue-forming portion, a runner-forming portion, a gate-forming portion, and a riser-forming portion. The sprue-forming portion forms an inverted conical sprue having a blade-lightener therein for quickly filling, and substantially simultaneously firing, the gates. A glue joint may be used between the pouring- basin-forming portion and the sprue-forming portion to increase the residence time of the melt in the pouring basin. The runners formed by the pattern each have an inline riser through which melt flows during pouring and in which melt is stored to feed the casting with melt during shrinkage of the casting A sand dam surrounds the mouth of each gate and traps particulates from a liquid styrene layer that precedes the melt front in the riser.

Abstract: A mold fill system for metal casting a mold, and associated method. The mold fill system comprises a horizontal primary runner defining a horizontal axis of rotation, a rotation mechanism for rotating the mold about the horizontal axis at an angular velocity, and a gating subsystem configured to receive metal flow from the primary runner and fill the mold uphill during rotation of the mold about the horizontal axis of rotation.

Abstract: A method of attaching a flexible plastic film having electronic circuit traces to a rigid plastic substrate. The film and substrate are made from different incompatible plastic materials that do not bond to one another and have different CTE. The use of different or incompatible materials is useful where the properties of the backing structure and film are selected to achieve different results. For example, the flexible film may be selected from a material that provides a high melting point to withstand soldering while the backing material is selected from a low-cost and light weight plastic material that has a lower melting point. The film has conductive traces on at least one surface thereof and a backing surface. A heat activated adhesive is applied to the backing surface. The film is placed within an open injection mold and the mold is closed. A hot plastic resin is injected into the mold adjacent the adhesive.

Abstract: A painted thermoplastic olefin (TPO) comprising a blend of elastomer and polypropylene. The polypropylene has a number average molecular weight of about 35,000 to about 70,000 and a polypropylene percent crystallinity of about 45 to about 70%. The elastomer has a number average molecular weight of about 20,000 to about 60,000 and an elastomer crystallinity of about 14 to about 60%. The TPO has a polypropylene to elastomer viscosity ratio of about 0.2:1 to about 30:1.

Abstract: A spray forming pattern of a first metal having a melting point at a first temperature is formed. The spray forming pattern has a surface defining a cavity that has the shape of a master pattern. Steel particles having a carbon content in the range of 0.01-0.9% by weight are sprayed onto the spray forming pattern to form a deposit on the spray forming pattern. The deposit has a thickness of at least 0.5 inches and the temperature of the steel particles increases as the thickness of the steel deposit increases. The spraying conditions are controlled so that the steel particles coming into contact with the spray forming pattern results in a surface temperature of the spray forming pattern of less than about 80.degree. C. The deposit and the spray forming pattern are heated to a second temperature, which is higher than the first temperature, to melt the spray forming pattern from the deposit. The resulting deposit has the general shape of the master pattern.

Abstract: A method is provided of determining windshield fog secondary for automatically controlling a heating, ventilation and air conditioning (HVAC) system of a vehicle. The method includes the steps of determining whether rain is occurring on a windshield of a vehicle, determining a windshield parameter as a function of the rain occurring and determining a temperature difference based on temperature within a cabin of the vehicle and ambient temperature. The method also includes the steps of determining a fog boundary based on the windshield parameter and temperature difference, determining a relative humidity based on the windshield parameter and the temperature difference and fog boundary and determining a fog probability based on the fog boundary relative humidity and a nominal base relative humidity for rain conditions. The method further includes the steps of determining anti-fog actions to be taken based on the fog probability and taking the anti-fog actions determined to control the HVAC system.

Abstract: A door assembly for an inflatable restraint system mounted in a motor vehicle includes a deployment door closing a deployment opening in vehicle structure. The door assembly also includes at least one tether connected to the deployment door and operatively connected to the vehicle structure to retain the deployment door to the vehicle structure after inflation of an inflatable restraint of the inflatable restraint system.

Abstract: A method of making a glass panel assembly for a motor vehicle includes a glass panel and a membrane mounted to one side of the glass panel. The glass panel mounting assembly also includes an adhesive disposed between the membrane and the glass panel, whereby the membrane is severed to allow the adhesive to secure the glass panel directly to vehicle structure.

Abstract: A glass panel assembly for a motor vehicle includes a glass panel and a membrane mounted to one side of the glass panel. The glass panel assembly also includes an adhesive disposed between the membrane and the glass panel, whereby the membrane is ruptured to allow the adhesive to secure the glass panel directly to vehicle structure.

Abstract: The invention is directed to a dark colored high-solids water-based paint composition comprising sodium silicate, water, water-soluble base, metal oxide pigment, a low-melting glass frit, and optionally, soda-lime-silica glass particles and/or zinc oxide. It may further optionally include surfactants and aluminum hydroxide. The paint composition is particularly useful as a black-out paint on automotive glazings.

Abstract: A method is disclosed of making a braze sheet for a brazed assembly. The method includes the steps of providing a sheet of a core material and a composition cladding and mechanically embedding a flux into the sheet.

Abstract: A method of initializing an in-car temperature sensor for a climate control system on a vehicle includes the steps of determining if a predetermined condition for initializing the in-car temperature sensor is satisfied and using an actual in-car temperature sensor output if the predetermined condition for initializing the in-car temperature sensor is not satisfied, and initializing the in-car temperature sensor output with an ignition-off in-car temperature sensor value if the predetermined condition for initializing the in-car temperature sensor is satisfied. The method also includes the steps of determining if a predetermined condition indicating not to use the initialized in-car temperature sensor output is satisfied and using an actual in-car temperature sensor output if the predetermined condition.

Abstract: A console is provided for use with an automotive vehicle. The console can be removed from or repositioned within a vehicle interior using an existing seating arrangement or seat fastening system. The console includes a variety of features, including use as a cooler or a seat separate from the vehicle. The console can be used in several positions within the vehicle.

Abstract: A taillight system for an automotive vehicle has an optic manifold mounted in a assembly defining a light emitting area, a first light source configured to provide illumination through the light emitting area, and a second light source configured to provide illumination through a predetermined portion of the light emitting area. The system has an illumination mode in which the first light source provides illumination of a first intensity in a first wavelength range through the light emitting area, a brake mode in which the first light source provides illumination of a second intensity in the first wavelength range through the light emitting area, and a backup mode in which the second light source provides illumination in a second wavelength range through the predetermined portion of the light emitting area, with or without the first light source providing illumination through the light emitting area, the second wavelength range including the first wavelength range.

Abstract: A molded article is prepared by forming a glass core, treating the glass core to induce residual stresses therein, inserting the core into a mold, injecting resin into the mold, curing the resin, fracturing the core to produce glass particles, and removing the glass particles from the molded article.

Abstract: A corrosion-resistant fiberglass spinner is prepared by applying consecutive, alternating layers of chromium and nickel to the bores of the spinner, and thereafter thermally interdiffusing the chromium and nickel to form a corrosion-resistant coating.

Abstract: A ventilation system (18) for a motor vehicle light fixture (10) comprises a rubber tube (20) adapted for connection to the light fixture (10), a filter (22) positioned within the rubber tube (20), and a hollow insert (24) having a plurality of baffles (30) positioned within the rubber tube (20) and adjacent the end of the tube exposed to the atmosphere.

Abstract: A durable, corrosion-resistant fiberglass spinner is prepared by applying a uniform layer of titanium nitride to the bores of the spinner by chemical vapor deposition, and applying over the layer of titanium nitride a layer of platinum by transient liquid phase deposition.

Abstract: A fuel tank having a fuel filler pipe, the filler pipe having a first end receiving fuel and a second end communicating with the interior of the tank; and a pervious conduit attached to the second end and extending into the tank below the fuel surface.

Abstract: The present invention provides an elastomeric-asphalt composition which does not phase separate and which is compatible at high temperatures. This compatible material can be produced without the need to use high shear milling equipment. The elastomeric-asphalt composition is not limited by the tendency of other elastomer polymers to be incompatible with asphalt nor does the composition separate into a polymer-rich phase and an asphalt-rich phase. In a preferred embodiment, the elastomeric materials are SBS and SIS block copolymers.