Abstract: A novel and improved closed nozzle injector is provided which effectively and accurately controls the timing and rate of fuel injection while minimizing parasitic losses and needle valve element wear. The closed nozzle injector includes a needle valve element movable between open and closed positions, an outer control volume, an injection control valve for controlling the flow of pressurized fuel from the outer control volume to affect opening and closing of the needle valve element and a needle valve biasing feature for optimizing the speed of needle valve opening and closing. The needle valve biasing feature includes an inner guide portion formed on the needle valve element with a larger diameter than an outer guide portion, an inner control volume, and an inner restriction orifice for restricting the flow of pressurized supply fuel to the inner control volume to create a fuel pressure bias closing force which advantageously slows down the opening of the needle valve element.

Abstract: A method for forming light-weight composite metal castings incorporating metallurgically bonded inserts for a variety of applications. Castings formed by the invention have particular utility as components of an internal combustion engine. A casting method includes the step of coating the insert with a first layer under conditions including sufficient temperature to cause a portion of the layer to be sacrificed by dissolving into the cast metal material while leaving at least a portion of the first layer as a diffusion barrier between the insert and the cast material. The molten casting material is treated and handled to keep the hydrogen content below 0.15 and preferably below 0.10 parts per million. The casting step takes place under a protective gas environment of dry air, argon or nitrogen with a moisture content of less than 3 parts per million.

Abstract: A variable geometry turbine and active wastegate are provided in combination along with independent control of the variable geometry turbine and wastegate valve so as to independently control exhaust gas recirculation flow and air flow in an internal combustion engine. Such independent control of exhaust gas recirculation flow and air flow in an internal combustion engine is achieved by providing a system for exhaust gas recirculation including an intake air manifold, an exhaust manifold, an exhaust gas recirculation passage providing fluid communication between the exhaust manifold and the intake air manifold, a variable geometry turbine positioned downstream of the exhaust manifold, and a waste gate passage providing fluid communication between the exhaust gas manifold and a point downstream of the variable geometry turbine.

Abstract: A radial flange coupling for joining a turbo-charger unit end housing to a turbo-charger center (or bearing) housing and for joining a turbine housing to an exhaust outlet connection including first and second arcuate jaws containing first and second radially inwardly opening grooves for clamping together flanged elements as the jaws are moved from an open to closed position wherein the jaws are hingedly joined by a connection that includes an extension integrally formed at the end of one jaw and extends through an opening in the other jaw and back to the first jaw where the distal end of the extension is affixed to the one jaw. The other ends of the jaws include end projections. One projection includes a threaded nut permanently affixed thereto. A threaded bolt having a reduced diameter pilot is provided for self piloting during assembly.

Abstract: A method for forming light-weight composite metal castings incorporating metallurgically bonded inserts for a variety of applications. Castings formed by the invention have a particular utility as components of an internal combustion engine. A casting method includes the step of coating the insert with a first layer which is followed by coating a second layer and concluded by a casting step under conditions including sufficient temperature to cause the second coated layer to be sacrificed by dissolving into the cast metal material while leaving at least a portion of the first layer as a diffusion barrier between the insert and the cast material. The molten casting material is treated and handled to keep the hydrogen content below 0.15 and preferably below 0.10 parts per million. The casting step takes place under a protective gas environment of dry air, argon or nitrogen with a moisture content of less than 3 parts per million.

Abstract: An improved fuel injection system is provided which incorporates a common rail and a plurality of unit injectors which function together to efficiently produce various injection rate shapes and different combinations of discreet and blended pilot, main, post and after treatment fuel injection events during a single injection. The fuel injection system effectively permits flexible, responsively timed, square shaped, discreet low to mid pressure level injections utilizing the fuel pressure of the common rail while also allowing the unit injector portion to function independently to produce flexible and responsively timed and pressure controlled, triangular shaped high pressure fuel injection events and to recover excess energy. In one embodiment, a separate common rail pump is avoided by utilizing the unit injector plunger to replace fuel into the common rail which was previously injected.

Abstract: An overload protection device for a manual hoist lever including a pressure hub, an outer hub, a brake nut, and a dowel pin. The pressure hub includes a radially extending flange and a cantilevered boss having a threaded outer surface with an axial groove. The outer hub includes a central opening, a tapered inner surface, and a flange contact surface which frictionally contacts the radially extending flange of the pressure hub. The brake nut is disposed in the central opening of the outer hub between the outer hub and the boss of the pressure hub, and includes a frusto-conical outer surface that frictionally contacts the tapered inner surface of the outer hub, as well as a threaded inner opening with a corresponding axial groove, the threaded inner opening being sized to threadingly engage the boss. The dowel pin is received within a receiving hole formed upon alignment of the axial groove of the boss and the corresponding axial groove of the brake nut.

Abstract: A fuel injection system is disclosed for an internal combustion engine that has multiple combustion chambers and a camshaft which cyclically imparts pressurization energy to and recovers pressurization energy from fuel being supplied to the engine. The fuel injection system includes a plurality of unit injectors, a camshaft linkage which simultaneously reciprocates pressurizing plungers of a set of at least two unit injectors and an interconnecting line which allows selective fluid interconnection between fuel pressurization chambers formed within the unit injectors. The interconnection line allows fluid linkage of the volume of fuel which is simultaneously pressurized and depressurized within the interconnected fuel pressurization chambers of a first set of unit injectors.

Abstract: A novel method and system for automatically removing an engine's used lubricating oil and injecting the used oil into the engine's fuel system throughout operation is disclosed. The lube oil removal system includes a removal and injection pump including a spring biased piston forming a chamber on each side. The lube oil removal system also includes a transfer circuit connecting the chambers and a pump control device for controlling the flow between the chambers. The pump control device also controls the flow of used oil from the engine to one of the chambers while a discharge circuit connects the other chamber to the engine fuel system. In a first position, the pump control device blocks the used oil from the engine while connecting the chambers and, in a second position, connects the used oil circuit to one of the chambers while blocking flow between the chambers.

Abstract: An improved pizza packaging system, pizza packaging blank and method for packaging more than one pizza in a stacked configuration and for delivery to a consumer comprising a pizza box having a bottom section and a lid panel. The bottom section includes a bottom panel bounded by a plurality of side panels extending upwardly from the bottom panel to define a pizza receiving compartment, the bottom panel being adapted to receive and support a first pizza. The lid panel is hingably attached to the bottom section in a manner to provide topographical access to contents placed within the pizza receiving compartment. An upper level insert is provided for insertion into the pizza receiving compartment, the upper level insert being elevated above the bottom panel and providing an upper level surface adapted to receive and support a second pizza.

Abstract: A microwave regenerable filter element including a filter media for filtering particulates from an exhaust gas, and a plurality of discrete heat generators disposed in the filter media, each of the plurality of discrete heat generators being adapted to absorb microwave energy and convert the microwave energy into heat. In one embodiment, the plurality of discrete heat generators may have a length dimension of substantially ½ of a microwave wavelength and a width dimension of substantially ⅛ of a microwave wavelength. In another embodiment, the plurality of discrete heat generators may be disposed in a spatial array in a manner that density of the plurality of discrete heat generators varies radially away from a central axis of the filter element. In yet another embodiment, the density of the plurality of discrete heat generators in the spatial array may also vary axially along the central axis of the filter element.

Abstract: A real-time mass flow measurement system that accurately measures fuel mass delivered to each cylinder per stroke of an injection pump or a fuel injector in an internal combustion engine. In accordance with preferred embodiment of the present invention, the mass flow measurement system and method includes a fuel measuring device that measures fuel delivered by one of the plurality of fuel injectors or fuel pumps. The preferred embodiment also includes a fuel transfer circuit for directing fuel flow to the fuel measuring device and a plurality of fuel diverting devices positioned along the fuel transfer circuit for diverting fuel flow from the plurality of fuel injectors or pumps into the fuel transfer circuit and a fuel routing device positioned along the fuel transfer circuit for routing the diverted fuel flow to either the fuel measuring device or a fuel drain.

Abstract: A computer implemented system and method for assisting in the visual analysis of the operational efficiency of major energy consuming systems at large facilities and particularly the consumption of electricity at commercial, governmental, or industrial facilities. The system and method allows for visually analyzing current and historic patterns of energy consumption in a facility (such as electricity, gas, steam, water or other energy) to determine the presence of possible operating errors, equipment problems, or hard-to-detect billing errors. An important step of the method is creating documented patterns representing unusual circumstances which could represent inefficient operation of the facility, for which solutions are known based on analysis of energy consumption by several large facilities over long periods, to allow identification of the nature of similarly inefficient facility operation as shown in the graphs produced by the disclosed method and to allow identification of possible solutions.

Abstract: A tappet assembly for an internal combustion engine, the tappet assembly having a first end mechanically connected to a engine component and second end adapted to contact a cam lobe of a camshaft to displace the engine component, where the tappet assembly includes a tappet body having a recessed pocket positioned at one end thereof, the recessed pocket being defined by an extended peripheral lip of said tappet body, a ceramic wear pad at least partially received within the recessed pocket, and a mechanism for preventing the ceramic wear pad from rotating relative to the recessed pocket. The ceramic wear pad has a top surface for contacting the cam lobe, a bottom surface which is received in the recessed pocket, and a peripheral edge surface thereinbetween.

Abstract: A piezoelectric actuator assembly that is insensitive to wide variations in operating temperatures including a stack of piezoelectric devices and a surrounding housing assembly formed of an outer cylindrical housing portion formed of steel having a coefficient of thermal expansion above that of the piezoelectric material and an inner cylindrical housing portion formed of Si—Ni ceramic. By arranging the inner and outer housing portions in parallel and forming the housing portions with appropriate cross-sectional areas, the housing assembly will have an effective coefficient of thermal expansion &agr;e that is equivalent to that of the piezoelectric element &agr;p.

Abstract: A network and method of operating a network of wireless service providers adapted to interact with a plurality of omni-modal wireless products within a given geographic area in a manner to permit the wireless service providers to “borrow” radio frequencies from other wireless service providers within the same geographic region. As a cellular service provider in a given region finds that one of its service areas or cells has become nearly or fully loaded, frequency could be borrowed from a competitor, such as a PCS provider serving the same region. Selected omni-modal wireless product users in the overloaded area would be told to switch their omni-modal to the “leased” frequency but to use the non-PCS communications protocol appropriate to the type of service desired by the user. Implementation of this method broadly within a given geographic region will have the effect of insuring that the available radio spectrum is used to its maximum capacity to serve the needs of the wireless users on a real time basis.

Abstract: The cellular telephone data communication system and method involves the use of a mobile data processing interface and a cooperating static data processing interface to effectively transmit data over a cellular telephone system. Each data processing interface includes a processor which operates in the transmitting mode to add an error control correction data format to data received from an external data source. The data is divided into packets and provided to a modem which is uniquely operated to eliminate the action of the modem scramble system and to remain active in spite of a carrier signal loss. The modem is deactivated or disconnected by a disconnect signal from the processor, and when carrier signal loss occurs, this disconnect signal is provided only after the lapse of a delay period without the resumption of the carrier signal.

Abstract: A laptop device includes a personal computer, a cellular transceiver, a speakerphone, and a hybrid communications control unit. The device has connectors for attaching a headset, cellular control unit, land telephone line, and additional speakers and microphones. The micro-processor-controlled hybrid communications control unit includes a modem, a data access arrangement, and a tone generator as well as digital, analog, and power switches. The hybrid communications control unit switches the communications components and provides, under program control, the proper protocols, level, and impedance matching to connect the modem, speakerphone, headset, speaker/microphone, or cellular control unit to the landline or to the cellular network via the transceiver. Matching and switching operations are automatic and transparent to the user. The unit can also connect two of the terminal devices or connect the cellular and landlines for call relaying. The device is capable of connecting plural calls at the same time.

Abstract: A laptop device includes a personal computer, a cellular transceiver, a speakerphone, and a hybrid communications control unit. The device has connectors for attaching a headset, cellular control unit, land telephone line, and additional speakers and microphones. The microprocessor-controlled hybrid communications control unit includes a modem, a data access arrangement, and a tone generator as well as digital, analog, and power switches. The hybrid communications control unit switches the communications components and provides, under program control, the proper protocols, level, and impedance matching to connect the modem, speakerphone, headset, speaker/microphone, or cellular control unit to the landline or to the cellular network via the transceiver. Matching and switching operations are automatic and transparent to the user. The unit can also connect two of the terminal devices or connect the cellular and landlines for call relaying. The device is capable of connecting plural calls at the same time.