Abstract: A headlamp assembly for a motor vehicle having a light source, a chamber that receives the light source and a cooling channel for removing heat from the chamber. A conductive wall and an insulating wall cooperate to define the chamber and the channel. The conductive wall has a substantially higher thermal conductivity than the insulating wall to promote the heat exchange between the chamber and the cooling channel and to reduce heat exchange between the cooling channel and the relatively hot engine compartment.

Abstract: A headlamp assembly for a motor vehicle including a lens and a housing that cooperate to define an inner chamber that is generally isolated from the atmosphere. A heat sink includes a fin portion that extends from the inner chamber so as to be exposed to ambient air. A light source is located within the inner chamber and is supported on a base portion of the heat sink. The heat sink conducts heat from the light source to air located exterior of the chamber.

Abstract: An automobile instrument panel assembly may be used in the cockpit of an automobile. The assembly includes a cross-car structure having a plurality of recesses and protrusions along the length of the structure and a plurality of generally planar surfaces. A plurality of HVAC components are adapted to closely fit within one or more of the plurality of recesses within the structure, and at least one flatwire bus is affixed to the generally planar surfaces of the structure.

Abstract: Flatwire assembly having a number of conductive elements or traces position on the substrate of the flatwire. In order to protect the conductive element from environmental hazards such as moisture and chemicals, a sealing film is provided that encapsulates the conductive elements. The sealing film has a polymer layer and an adhesive layer. The polymer layer prevents vertical diffusion of moisture into the conductive elements and the adhesive layer prevents later diffusion of moisture. The sealing film is larger than the conductive elements such that it completely encapsulates the conductive elements.

Abstract: A multi-layer circuit board having apertures that are selectively and electrically isolated from electrically grounded member and further having selectively formed air bridges and/or crossover members which are structurally supported by a polymeric material. Each of the apertures selectively receives an electrically conductive material.

Abstract: A vehicle lamp that includes an integrated sensor for interacting with an operating environment of a vehicle is provided. The vehicle lamp includes a sensor and a light channel adapted to transmit data received by the sensor. The vehicle lamp can also include a flat wire that has a component integrally formed by the light channel. A vehicle illumination and data transmission system is also provided. The system includes vehicle lamps according to the present invention, and can include sensor processors located within each of a plurality of lamps, or sensor processors that are centrally located within the vehicle. A system processor is connected to the sensor processors and enables operating decisions based upon data received from the environment by the sensors.

Abstract: Flatwire assembly comprises a number of conductive elements or traces position on the substrate of the flatwire. In order to protect the conductive element from environmental hazards such as moisture and chemicals, a sealing film is provided that encapsulates the conductive elements. The sealing film comprises a polymer layer and an adhesive layer. The polymer layer prevents vertical diffusion of moisture into the conductive elements and the adhesive layer prevents later diffusion of moisture. The sealing film is larger than the conductive elements such that it completely encapsulates the conductive elements.

Abstract: A method for making a multi-layer circuit board 116 having apertures 96, 98 which may be selectively and electrically isolated from electrically grounded member 46 and further having selectively formed air bridges and/or crossover members 104 which are structurally supported by material 112. Each of the apertures 96, 98 selectively receives electrically conductive material 114.

Abstract: A method for making multi-layer electronic circuit boards 64 having “blind” type apertures 28, 30 which may be selectively and electrically grounded and further having selectively formed air bridges and/or crossover circuits 45, 46.

Abstract: A method for making a multi-layer circuit board 116 having apertures 96, 98 which may be selectively and electrically isolated from electrically grounded member 46 and further having selectively formed air bridges and/or crossover members 104 which are structurally supported by material 112. Each of the apertures 96, 98 selectively receives electrically conductive material 114.

Abstract: An automobile instrument panel assembly for the cockpit of an automobile. The assembly includes a cross-car structure having a plurality of recesses and protrusions along the length of the structure and a plurality of generally planar surfaces. A plurality of HVAC components are adapted to closely fit within one or more of the plurality of recesses within the structure, and at least one flatwire bus is affixed to the generally planar surfaces of the structure.

Abstract: A vehicle lamp that includes an integrated sensor for interacting with an operating environment of a vehicle is provided. The vehicle lamp includes a sensor and a light channel adapted to transmit data received by the sensor. The vehicle lamp can also include a flat wire that has a component integrally formed by the light channel. A vehicle illumination and data transmission system is also provided. The system includes vehicle lamps according to the present invention, and can include sensor processors located within each of a plurality of lamps, or sensor processors that are centrally located within the vehicle. A system processor is connected to the sensor processors and enables operating decisions based upon data received from the environment by the sensors.

Abstract: A system for controlling a vehicle powertrain is disclosed. The system includes a powertrain circuit for receiving a plurality of powertrain operating signals, processing the operating signals, and outputting a plurality of powertrain control signals for controlling the vehicle powertrain, and an air-intake manifold fixable to an engine of the vehicle powertrain and adapted to receive the powertrain control circuit. The present invention provides a self-contained vehicle powertrain that is testable before installation into a motor vehicle.

Abstract: A braking unit is provided. In one embodiment, the braking unit comprises a base member, a guide member, a flexible rod, an actuator adapted to induce deformation of the rod, and a brake pad. One end of the flexible rod is fixedly attached to the base member while another end is slideably disposed within a passageway defined by the guide member. The brake pad is positioned adjacent the flexible rod such that deformation of the rod causes lateral movement of the brake pad. The braking unit can be incorporated into disc and drum-type braking assemblies and systems.

Abstract: A vent assembly that can be concealed when in a closed configuration is provided in one embodiment, the vent assembly comprises a base member and a guide member secured to a mounting surface of a duct or other passageway. A flexible rod is fixedly attached to the base member and slideably disposed within a channel defined by the guide member. A panel is disposed on or around the flexible rod and between the base and guide members. An actuator is able to deform the rod such that the panel moves away from the terminal opening of the duct, thereby opening the vent. A fluid distribution system incorporating vent assemblies in accordance with the present invention is also provided.

Abstract: A system for controlling a vehicle powertrain is disclosed. The system includes a powertrain circuit for receiving a plurality of powertrain operating signals, processing the operating signals, and outputting a plurality of powertrain control signals for controlling the vehicle powertrain, and an air-intake manifold fixable to an engine of the vehicle powertrain and adapted to receive the powertrain control circuit. The present invention provides a self-contained vehicle powertrain that is testable before installation into a motor vehicle.

Abstract: A container holder for receiving and securing a container is provided. In a preferred embodiment, the container holder comprises a base surface, at least one moldline structure unit, and a sensor. The sensor detects the presence of the container in the holder and induces deformation in the moldline structure unit such that the container is secured in the holder.

Abstract: A method for making multi-layer electronic circuit boards 64 having “blind” type apertures 28, 30 which may be selectively and electrically grounded and further having selectively formed air bridges and/or crossover circuits 45, 46.

Abstract: Positioning of sensitive electronics near the engine block is accomplished through the use of a heat shield providing for removal or diversion of transmitted heat from the block to the electronics through the use of a self-contained or externally circulated coolant fluid. Unlike conventional coolant channels in an engine block, the heat shield is not intended to cool the engine block and thus may be more compact insofar as it deals with lesser heat flux.

Abstract: Conductors supported integrally with engine structure such as air intake manifolds and the like provide interconnection between engine components without the need for separate conventional wiring harnesses. The conductors take their mechanical strength from the underlying physical object and thus can be lighter than a freestanding harness. Connectors allow traces to continue across points of mechanical interface between structural components and allow wiring of engine components to be accomplished in the same operation as their physical assembly.