Abstract: The present invention relates to a hybrid frame rail including a pair of metallic flanges separated by a composite web including a first and second sections, each section including a pair of elongated bands separated by a transversely extending wall which includes a plurality of protrusions integrally connected to complimentary protrusions provided on the complimentary web section. To manufacture the hybrid frame rail, the metallic flanges are attached over the elongated bands of the web such that the web is entrapped between the metallic flanges.

Abstract: A modular system for the support and positioning of a workpiece for use with a device such as an inspection system. The system includes a base having a plurality of exterior faces, at least some of which have an array of equally spaced holes forming a grid pattern. At least one riser is attached to the base cube by a fastener, which can be inserted into the riser by defeating an outwardly biased locking member at the inner end of the fastener, extending through said riser and into the holes of the base cube. The fastener is used to provide positive location and fastening of the risers to the base cube. Functions of individual risers include support, clamping, datum point positioning and providing reference points.

Abstract: A method for adhesively joining two members includes the steps of mixing non-compressible beads with an adhesive, applying the resulting mixture to one of the members and hemming one member over the other in overlapping relationship. Apparatus for performing this method includes a container for containing a mixture of an adhesive and a plurality of non-compressible beads, an applicator for applying the mixture to one of the members, and hemming means for hemming one member over the other in overlapping relationship. A metering device for dispensing adhesive fluid is constructed with a dispensing rod having a cooling means for facilitating operation of the metering device. The present invention finds particular utility in bonding together the inner and outer panels of an automotive door assembly.

Abstract: Disclosed is a contact pouring vessel and method for pouring molten metal directly into a mold. A pouring vessel holds the molten metal in a molten state. A nozzle within the pouring vessel and having an orifice enables the molten metal to pour from the pouring vessel. A stopper rod is raised or lowered to either seal the orifice or permit the molten metal to flow out the pouring vessel. A rotating cutter cleans the bottom of the nozzle each time a mold is filled to prohibit an unwanted buildup on the nozzle. Four hydraulic cylinders and a hydraulic system are used to controllably raise and lower the pouring vessel. The pouring vessel is raised to accommodate the positioning of mold adjacent the nozzle and lowered to position the nozzle flush with the mold.

Abstract: An inboard bearing retainer for use in a vehicle wheel assembly having a live spindle. The inboard bearing retainer includes a retaining nut adapted to be engaged to an outer diameter of the inboard end of the live spindle. The nut including a flange which provides inboard retention and restrains inboard movement of the wheel bearing relative to the live spindle. The nut also includes a surface which at least partially defines the bearing seat for the wheel bearing. The retaining nut is engaged by a locking assembly mounted to the spindle's inboard end so as to prevent disengagement of the retainer nut from the spindle. In one embodiment, the locking assembly is a one-piece body having a bearing portion, a thrust washer portion and locking tabs which interferingly prevent disengagement of the retainer nut from the live spindle.

Abstract: The present invention relates to a hybrid frame rail including a pair of metallic flanges separated by a convoluted web including a plurality of alternately opposing recesses extending transversely to the flanges. In manufacture, the convoluted web is generally adhesively bonded to the flanges to form the hybrid frame rail.

Abstract: A composite cast caliper in which the body of the caliper is cast with an additional component embedded therein. The embedded or intra-cast component can be either a reinforcing structure to strengthen and prevent deflection of the caliper body or it can be a tube providing a coolant passage within the caliper. The coolant passage tube is connected to a source of coolant fluid for circulation through the caliper to remove heat therefrom. The embedded component is positioned within the casting mold by the use of a plurality of locating wires.

Abstract: A test apparatus for testing hem flanges that join automotive body panels is provided. This testing apparatus operates by engaging a hook member with a first body panel such that the first body panel is maintained in a held relationship with respect to the hook member. A ram member then extends from the testing apparatus and engages with and loads a second automotive body panel member. As a result, a tensile load is applied to the hem flange, permitting the hem flange to be analyzed for defective construction.

Abstract: A composite brake disc and drum assembly for a motor vehicle having a rear disc brake system and a parking brake system. The assembly includes a body of a first material having a mounting web, a skirt and a flange. The skirt extends from the perimeter of the mounting web and cooperates therewith to define a brake drum. The skirt has an inside surface which defines a cylindrical braking friction surface for engagement with the parking brake shoe. The flange extends outward from the skirt and at least one annular plate is supported by the flange so as to extend in a plane generally perpendicular to the axis of rotation. The plate includes a surface defining an annular braking friction surface for engagement with the disc brake pads.

Abstract: A simple yet reliable sealing assembly for a vacuum compression mold. Molding apparatus for compression molding a charge under vacuum includes an upper die having a molding surface and outer side walls. A lower die has a complimentary molding surface and side walls substantially aligned with the side walls of the upper die. A heat source heats the upper and lower dies. A sealing assembly includes a seal plate on each side wall of the upper die. Upper portions of the seal plates are fixed and sealed to the upper die. Lower portions of the seal plates extend downwardly therefrom. The sealing assembly includes flexible sealing tubes on lower portions of the plates. A distance between upper and lower edges of the seal plates is related to a height of the charge to be molded. A moving device moves the upper die towards the lower die to a partially closed position where the tubes of the sealing assembly engage side walls of the lower die to thereby create a vacuum chamber.

Abstract: An inboard bearing retainer for use in a vehicle wheel assembly having a live spindle. The inboard bearing retainer includes a retaining nut adapted to be engaged an outer diameter of the inboard end of the live spindle. The nut including a flange which provides inboard retention and restrains inboard movement of the wheel bearing relative to the live spindle. The nut also includes a surface which at least partially defines the bearing seat for the wheel bearing. The retaining nut is engaged by a locking assembly mounted to the spindle's inboard end so as to prevent disengagement of the retainer nut from the spindle. In one embodiment, the locking assembly is a one-piece body having a bearing portion, a thrust washer portion and locking tabs which interferingly prevent disengagement of the retainer nut from the live spindle.

Abstract: A steering knuckle assembly for a motor vehicle. The steering knuckle assembly includes a stamped knuckle housing which provides attachment points for various suspension components, including a steering arm. The knuckle housing is formed with a pair of generally spaced apart, opposing side walls being connected by an integral transverse wall. Opposite of the transverse wall, a steering arm link bridges the gap between the side walls thereby increasing the resistance of the knuckle housing to bending and torsional loads. Extending off of one end the steering arm link is a mounting arm which provides an attachment point for the steering arm.

Abstract: A composite brake rotor for a motor vehicle wheel assembly. The rotor includes an annular braking plate having a braking friction surface and at least one reinforcement ring cast so as to extend circumferentially within the braking plate. The reinforcement ring provides structural reinforcement to the braking plate thereby inhibiting checking and crack formation in the rotor.

Abstract: A unitary hub and exciter ring for a motor vehicle equipped with an anti-lock braking system (ABS). The exciter ring is unitarily formed in the hub by machining grooves into the exterior surface of the hub and creating spaced teeth about the circumference of the hub. To ensure roundness and concentricity in the hub, and to ensure close tolerances in spacing between the ABS sensor and the teeth, machining is gaged off of bearing cups mounted within the internal bore of the hub.

Abstract: A diesel heater includes a combustion chamber and a fuel pump for pumping diesel fuel to the combustion chamber. An air supply device supplies combustion air to the combustion chamber. An igniter ignites the diesel fuel to generate combustion heat. A heat exchange fluid supplying device supplies fluid in heat exchange relationship with the combustion heat. A thermal sensor in contact with the heat exchange fluid generates a temperature signal related to the temperature of the heat exchange fluid. A flame detector detects an ignited diesel fuel flame and generates a flame signal in response thereto. A microprocessor includes a memory and a plurality of input/output ports wherein the input/output ports are electrically connected to the thermal sensor, the fuel pump, the heat transfer fluid supplying device, the igniter, the combustion air supply device, and the flame detector. The memory stores a normal operating sequence, a start-up sequence, and a tail start period for the start-up sequence.

Abstract: A fiber reinforced plastic fuel tank includes a multipurpose inner liner that serves as an aid during molding as well as a corrosion resistant protector and/or secondary fuel container for the tank when in use.

Abstract: A wheel hub assembly for a non-driven axle including a hub, a bearing retainer ring and a bearing. The bearing retainer ring is secured to the hub by engagement of the wheel mounting studs with the hub. A portion of the bearing retainer ring directly engages and positively provides an axial retention load on the bearing. The resulting structure is a compact and light weight wheel hub assembly having simplified, cost efficient construction.

Abstract: A bucket elevator system for a waste water treatment facility is made of non-metallic components. Buckets are carried along a bottom surface of a settling tank and then lifted above the waste water level and tilted to dump the collected waste solids onto an external disposal system. The buckets include a plurality of de-watering slots which allow the water to drain from the buckets as they are lifted from the settling tank. Split block bearing assemblies are provided for drive shafts of the conveyor.

Abstract: An integral hub and exciter ring is disclosed for a motor vehicle equipped with an anti-lock braking system in which the exciter ring is integrally formed with the hub by machining grooves into the hub forming spaced teeth about the circumference of the hub. To improve the magnetic permeability of the teeth as compared to the cast iron of the hub, a steel band is insert cast into the hub resulting in a steel band having improved magnetic permeability and also being molecularly bonded to the cast iron to ensure retention of the band in the hub.

Abstract: A vehicle door assembly including a tailored steel inner panel and an panel spaced apart by a belt-line reinforcement member. The tailored steel inner panel includes an intrusion beam which bridges first end and second ends of the inner panel.