Abstract: A method and apparatus for forming and mounting a sleeve and a thrust member in a bore in a motor/gear drive housing shaft to support the motor/gear drive shaft against radial and axial movement. Gates are formed in the motor/gear drive housing and communicate with separate first and second bores in the housing. A mold core is inserted into the housing and closes off one bore to allow the injection of molten plastic into a cavity formed between the tip end portion of the mold core and the first bore to form an annular sleeve. The annular sleeve has an inner diameter larger than the outer diameter of the end tip portion of the motor/gear drive shaft to be nominally spaced from the outer diameter of the drive shaft, but is supportingly engaged by the drive shaft under radial deformation of the drive shaft.

Abstract: A heat source is disposed in a thermally conductive mass for imparting heat to the mass. Fluid in a flow path through the mass absorbs heat from the mass. One or more heater elements forming the heat source are disposed in direct contact with the mass. A ground plate connected to a ground terminal is fixedly connected to the heater elements, either on a portion of the heater elements extending exteriorly of the mass, on a portion of the heater elements disposed within the mass, or substantially all the ground plate insert molded in the mass on the heater elements. Alternately, the ground member is insert molded in the mass separate from the heater elements, but connects electrical heater elements to ground through the mass.

Abstract: A ball nut has at least one internal bearing race with a first end and second end, and at least one recirculating crossover passage for connecting the first end with the second end of the bearing race to form a continuous recirculating path for a plurality of ball bearings. A method for producing a ball nut includes the steps of forming at least a portion of the ball nut body with a helix passage for receiving a plurality of ball bearings, forming a crossover passage in communication with the helix passage for returning the plurality of ball bearings to an opposite end of the helix passage, and assembling the ball nut body portions to position the helix passage and operable orientation with respect to the crossover passage to define at least one raceway having a single recirculating rotational path for receiving the plurality of ball bearings. The ball nut body can be formed by being drawn, coined, metal injection molded, roll formed, through rolled, stamped and/or overmolded.

Abstract: A method and apparatus for controlling fluid temperature in a fluid heater apparatus which supplies heat to fluid from a controllable heater element(s) which includes establishing a discharge temperature range between a first high temperature and a second low temperature. The temperature of the fluid is measured and, in response to the measured temperature, activation of the heater elements is controlled to maintain the temperature of the fluid within the temperature range. The heater elements can be independently controllable for temperature control.

Abstract: A wiper apparatus for a vehicle windshield has a wiper arm pivot rotatably mounted in a pivot holder fixedly secured to vehicle structure. An end portion of the wiper arm pivot normally extends exteriorly of an impact line defined by surrounding vehicle structure. The wiper arm pivot is axially displayable relative to the pivot holder upon the imposition of an impact load on the exposed end of the wiper arm pivot. An axial displacement biasing member is coupled to the wiper arm pivot for normally biasing the wiper arm pivot to a normal wiper arm wiping position. The axial displacement member returns the wiper arm pivot to the nominal wiping position after the impact load causing axial displacement of the wiper arm pivot has been removed from the wiper arm pivot.

Abstract: An electric motor and method for reducing or eliminating end play. The motor comprises an adjustment member that cooperates with an end lamina member to facilitate reducing end play. The adjustment member is slidably mounted on an armature shaft and inside an aperture of a portion of the end lamina tube to reduce or eliminate end play. Thereafter, the adjustment member is permanently secured to the end lamina tube. In another illustrative embodiment, the movable bearing retainer sets endplay and also retains brushes in an open position prior to, for example, assembly of the motor.

Abstract: A segmented stator for a permanent magnet motor. The stator includes a plurality of stator segments forming an annular stator yoke and a plurality of stator teeth extending from an edge of the stator yoke. At least one coupling is between adjacent stator segments and shaped to allow movement of adjacent teeth in a so-called loose tooth design. Slot wedges are located between adjacent teeth to prevent the conductive windings from moving out of the slots through the slot openings. The slot wedges also prevent movement of adjacent teeth with respect to one another. The segmented stator can comprise an annular yoke with a plurality of discrete teeth or a plurality of assemblies including a rim section and a tooth section. The slot wedges can be keyed wedges that maintain their position through interlocking and/or can be integrated with a stator bobbin.

Abstract: A fluid heater apparatus has fluid discharge temperature control to prevent temperature overshoot. A plurality of heater elements are employed and at least certain of the heater elements are independently controllable. At least one of the heater elements is employed as a “finishing” heater element, with the other heating elements deactivated to enable the “finishing” heater element to more slowly elevate the temperature of the fluid in the body from a first temperature reached by activation all or most of the heater elements to the predetermined discharge temperature. One of more of the heater elements may have a different power output than the other heater elements.

Abstract: An automotive steering assist system having an electric motor provided with poles organized into 2 groups. The motor has means for detecting shorts in the poles and means for disabling all poles in a pole group whenever a short is detected in a pole of that group.

Abstract: Torque generating apparatus and method for automotive applications. A brushless DC motor is design optimized to operate at a design voltage, Vs, along an optimal speed/torque profile. A DC/DC converter is provided for supplying power at an alternate voltage, Va, to enable motor operation at speed/torque combinations not on the optimal profile. A switch is provided to enable the motor to be operated selectively at either of the two voltages.

Abstract: A module in the form of an applique is mountable on an exterior surface of a vehicle liftgate and provides a mounting platform for a plurality of components mountable on the liftgate in a single assembly operation. The components include at least two of light sources in the form of LEDs or incandescent bulbs, an actuatable switch, a camera and a wash fluid dispensing nozzle. The components are mounted on a substrate in the form of a printed circuit board or a lead frame attached to a substrate for mounting in a carrier. The carrier is affixed to the module and is alignable with apertures in the applique for transmission of light from the light sources exteriorly of the applique as well as to enable the camera to view a field of view through the lens. The electric switch is actuatable by a resilient membrane mounted on the carrier and actuatable exteriorly of the applique.

Abstract: This invention relates to windshield wiper system which utilizes a flexible drive arm for withstanding bending loads applied to a wiper. The drive arm may be made of a pull-molded composite material having a relatively low modulus of elasticity and a relatively high elongation factor. The flexible arm twists in the presence a bending load and undergoes rapidly progressing elastic buckling when the bending load exceeds a predetermined amount.

Abstract: A liftgate component module mountable on a pivotal liftgate window provides a unitary mounting platform for a plurality of components including a window wiper drive motor and a window latch. A unitary bracket carries the wiper drive apparatus and the window latch apparatus. A handle, which may include an electrical switch, is also mounted on the window. The electrical connections between the handle switch and a controller carried on the window as part of the motor enables instantaneous response of the latch to activation of the handle switch. The same controller can also control a liftgate latch and a liftgate electrical switch handle.

Abstract: The apparatus and method includes a panel movable between at least two positions. An electric motor has a rotating armature. A multiple pole magnet is mounted on the armature. A sensor detects the passage of each magnet pole and generates an output signal. A control measures time periods between each pole passage. An average time period is computed over a predetermined number of time periods. The difference between average time periods is computed and compared with a threshold difference to determine if an obstacle is present in the path of movement of the panel. Transient counts are accumulated for increasing average time periods over a number of time period samples as a measurement of the force exerted on an obstacle by the panel to detect an obstacle.

Abstract: A wiper arm and method for manufacturing a wiper arm provides a body having a first end connectible to and supportable by a drive shaft for imparting oscillatory rotary movement and a second end connectible to and supporting a wiper blade. A torsional region of the body is capable of toggle action and is located between the first and second ends of the body. The toggle action is defined by two stable positions, a primary position and a secondary position, lying spaced at opposite sides of an unstable range of movement, where one of the two stable positions exerts downward pressure on the wiper blade connectible to the body for engagement against a windscreen to be wiped. The torsional region is defined by first and second torsional members initially formed in a relaxed state. Each torsional member has a free end cantilevered outwardly from the first end of the body and spaced from one another. Each torsional member is subsequently flexed into a flexed state such that the free ends engage one another.

Abstract: An apparatus for aligning and supporting a rotatable shaft through a plastic molded support member includes an integral boss formed in the plastic molded support allowing insertion of the rotatable shaft to be supported therethrough. At least one bearing is associated with the boss for establishing proper orientation of a rotational axis of the rotatable shaft to be mounted through the boss. At least one bearing is press fit into the boss. In the preferred configuration, a pair of hat-shaped cylindrical bearings are press fit in opposite ends of the boss to define the rotational axis of the shaft to be mounted through the boss.

Abstract: A novel system, surgical method, and tools for performing a total ankle replacement are described. The total ankle replacement system includes the calcaneus in fixation of a lower prosthesis body, thereby significantly increasing the amount of bone available for fixation of the lower prosthesis body and allowing the lower prosthesis body to be anchored with screws. The total ankle replacement system further includes a long tibial stem which can also be anchored into the tibia The novel surgical arthroscopic method allows introduction of ankle prostheses into the ankle joint through an exposure in the tibial tubercle. Various novel surgical instruments, such as a telescoping articulating reamer and a talo-calcaneal jig, which facilitate the novel surgical method, are also described.

Abstract: A method and apparatus for forming and mounting a sleeve and a thrust member in a bore in a motor/gear drive housing shaft to support the motor/gear drive shaft against radial and axial movement. Gates are formed in the motor/gear drive housing and communicate with separate first and second bores in the housing. A mold core is inserted into the housing and closes off one bore to allow the injection of molten plastic into a cavity formed between the tip end portion of the mold core and the first bore to form an annular sleeve. The annular sleeve has an inner diameter larger than the outer diameter of the end tip portion of the motor/gear drive shaft to be nominally spaced from the outer diameter of the drive shaft, but is supportingly engaged by the drive shaft under radial deformation of the drive shaft.

Abstract: An end play restriction wedge restricts the end play of a rotatable shaft with respect to a housing. The end play restriction wedge includes a female-wedge housing and a male wedge. The female-wedge housing has a U-shaped cross-section defined by an intermediate wall and outwardly extending side walls connected adjacent each end of the intermediate wall. The intermediate wall has a thrust plate surface along one side and an angled ramp along an opposite side. The angled ramp and outwardly extending side walls define a tapered aperture extending through the housing with an enlarged opening adjacent a first end of the housing. The male wedge is positioned adjacent the enlarged opening of the housing to be driven into the tapered aperture in response to an external force acting on an outer end of the wedge.

Abstract: An optical moisture detector for determining a value corresponding to ambient light conditions and comparing that value to a predetermined value. The detector includes an optical moisture sensor and a processor. The optical moisture sensor can be a photo array, a CCD or a CMOS. The processor can be a microprocessor. The processor can emit a control signal to engage or disengage a light generating device based on the result of the comparison of the value to the predetermined value.