Abstract: A three-way gas control valve assembly for selectively controlling gas flow from one inlet port into two outlet ports or vice-versa, such as may be required for flow control of hydrogen-containing reformate in fuel cell applications. The valve assembly comprises three subassemblies: a metering subassembly disposable within the high-temperature environment in the fuel cell for mechanically regulating reformate flow; an actuating subassembly disposable outside the fuel cell and connected to the metering subassembly for actuating a pintle shaft and valve head in the metering subassembly; and a coupling tube subassembly extendable through an insulative shroud to mechanically couple and thermally isolate the metering and actuating subassemblies.

Abstract: A hydraulic control system for controllably directing pressurized engine oil to deactivation valve lifters to activate or deactivate the associated engine intake and exhaust valves. Passages to the lifters are controllably opened or closed by a solenoid control valve responsive to signals from a computerized engine control system. Preferably, the hydraulic control system includes a top plate having a first pattern of channels and bores formed in its underside, and a bottom plate having a second such pattern formed in its upper surface. The top and bottom plates are joined to form a hydraulic distribution manifold mounted on the engine. In a presently preferred embodiment, a gasket plate having bores and patterns of resilient gasketing material is provided between the top and bottom plates to simplify fabrication of the top and bottom plates.

Abstract: A process for forming a roller bearing comprising the steps of providing a cylindrical slug that comprises at least 0.7 weight percent carbon and up to 1.6 weight percent of at least one alloying element. The slug has lateral and side surfaces. A centered indentation is formed in each side surface. A circular chamfer surface is formed at the intersection of each side and each lateral surface, thereby producing an upsetting slug. The upsetting slug is cold formed, thereby deepening the centered indentations and forming a blank. The blank has a web separating the deepened indentations and end surfaces and chamfer surfaces that are substantially at net shape for the roller bearing. The web is removed from the blank, thereby forming a pierced blank having a through hole with an inner surface. The inner and lateral surfaces of the pierced blank are finished to the specified inner and outer diameters for the roller bearing.

Abstract: A leakage arresting system comprising a novel gas arrestor for installation on an interrupted pintle shaft in a pintle-type valve, such as an exhaust gas recirculation valve for an internal combustion engine, for preventing leakage of gas and moisture along the pintle shaft into the actuator, to prevent corrosion and failure of the actuator. The system comprises two elements: a pintle shaft which is interrupted outside the actuator, and a positive vapor block in the form of a cup-shaped arrestor disposed across the pintle interruption. The invention is applicable to both unbalanced and force-balanced valves.

Abstract: A rocker assembly has a first arm for following a first or opening camshaft lobe, a second arm for following a second or closing camshaft lobe, and a pivot axis of the rocker arm therebetween. A captive roller follower on the first arm follows the first lobe, and a slider on the second arm follows the second lobe. An eccentric pivot pin for the rocker assembly is rotatable to change the location of the pivot axis of the rocker assembly with respect to the captive roller and the slider, to adjustably set mechanical lash among these components after installation of the rocker arm assembly into a variable valve mechanism of an internal combustion engine.

Abstract: A method of assembly of a fuel injector having a valve plunger reciprocable in a guide tube for movement from a closed position engaging a valve seat to an open position engaging a valve stop by energizing of a solenoid coil to move the plunger against a biasing spring, wherein the method includes setting the valve stop at a position effective to establish the desired valve stroke, and fixing the valve stop to the guide tube by first laser spot welding the valve stop in the guide tube to fix the position of the valve stop without changing the set gap, and then laser seam welding the valve stop in the guide tube at an axial location beyond the spot welds, relative to a plunger-engagable end of the valve stop, to provide a hermetic seal around the valve stop.

Abstract: A method is provided for assembling a pole piece into an internal fuel passage of a fuel injector. The assembly method includes the steps of: (a) providing an endoskeletal injector tube, where the injector tube provides the fuel passage for the fuel injector; (b) forming at least one depression into an outer surface of the injector tube; (c) inserting an injector valve into the injector tube; (d) inserting the pole piece into the injector tube, wherein the pole piece is adjustable thereafter; and (e) affixing the pole piece within the injector tube, where an outer surface of the pole piece is in contact with an inner surface of the injector tube corresponding to the depressions, thereby creating a spring fit between the pole piece and the tube.

Abstract: An engine management system for an internal combustion engine for an automobile includes an architecture for a super ultra low evaporative emission capability. In the present architecture, the fuel rail and injectors are located within the intake manifold such that permeating and evaporative emissions are contained within the intake manifold and a sealing throttle body and/or shut-off check valve is located between the air cleaner/induction components and the throttle body prevent hydrocarbon emissions from reaching the atmosphere. Additionally, a shut-off valve and/or programmable valve train are included to prevent hydrocarbons from the PCV valve and fresh air supply line from being vented to atmosphere. A one way check valve is located between the air induction and cleaner and the PCV fresh air supply such that hydrocarbons that are produced within the intake manifold may pass into the PCV fresh air supply line.

Abstract: An exhaust gas re-circulation (EGR) system is provided for use in conjunction with an internal combustion engine. The EGR system includes an intake manifold, an exhaust manifold, a passageway connected in flow communication between the exhaust manifold and the intake manifold, and an EGR valve interposed in the passageway for controlling re-circulation of exhaust gas into the intake manifold. In addition, an emissions control device (e.g., a catalytic converter) for reducing exhaust emissions in the gas flowing into the intake manifold is connected in flow communication with the EGR valve.

Abstract: An actuator includes a cylinder having a central axis and a side wall. The side wall has an inner surface. A clutch is disposed within the cylinder, and includes a hub and at least one clutch arm. Each clutch arm includes a negative opposing finger, a positive opposing finger, a negative opposing spring and a positive opposing spring. The negative opposing finger has a first end attached to the hub and a fingertip end engaging the inner surface of the side wall. The positive opposing finger has a first end attached to the hub and a fingertip end engaging the inner surface of the side wall. The negative opposing spring has a first end attached to the negative opposing finger. The positive opposing spring has a first end attached to the positive opposing finger. A control input is configured for engaging a second end of a selected one of the negative opposing spring and the positive opposing spring.

Abstract: A pressure atomizer includes a silicon plate having a top surface and a bottom surface. A portion of the top surface defines a turbulent chamber. The turbulent chamber is peripherally bounded by the top surface of the plate. The turbulent chamber is recessed a predetermined depth relative to the top surface. The silicon plate further defines at least one flow orifice. Each flow orifice extends from the bottom surface of the silicon plate to intersect with and open into the turbulent chamber. Each flow orifice is in fluid communication with the turbulent chamber.

Abstract: A hydraulically actuated exhaust gas recirculation valve assembly for metering exhaust gas to the intake of an internal combustion engine. The exhaust gas recirculation valve assembly includes a base having an internal cavity with a control portion and a flow-through portion permitting flow-through of exhaust gas. The base has a hydraulic control port in fluid communication with the control portion of the cavity, the control port having an inlet. A valve body is rotationally mounted within the base, the valve body including a hydraulic control spool disposed within the control portion of the internal cavity. The hydraulic control spool generates a rotational force in response to a hydraulic pressure applied to the control port.

Abstract: A variable valve mechanism includes an elongate input shaft having a central axis. An input cam lobe is disposed on the input shaft and is eccentric relative to the central axis. A guide member is pivotally mounted on the input shaft. A frame is disposed in engagement with the input cam lobe, and is pivotally and slidably coupled to the guide member. A link has a first end pivotally coupled to the frame. An output cam is pivotally mounted on the input shaft. The output cam is pivotally coupled to a second end of the link arm. The output cam is configured for oscillating engagement of a roller of a roller finger follower.

Abstract: A cam phaser wherein the stator is integral with either the back plate or the front cover plate. The integral stator may be formed by any desired forming technique, such as, for example, by machining, casting, welding, or injection molding. Preferably, however, the integral stator is formed in a single molding step by powdered metal forming using powdered aluminum. Cap seals are provided for sealing the hydraulic chambers of the cam phaser.

Abstract: A fuel injection system is provided for use in an internal combustion engine, where the engine includes at least one cylinder head cover. The fuel injection system includes at least one fuel injector assembly that is inserted into an inlet in the cylinder head cover. The fuel injector assembly includes an upper body portion and a lower body portion that extends through the inlet of the cylinder head cover, where at least part of the lower body portion is comprised of a low radiant heat absorbent material having a high radiant heat reflectance color for reflecting radiant heat away from the fuel injector assembly during engine operating conditions.

Abstract: An integrated fuel delivery module for a fuel injected engine includes a fuel rail having a fuel distribution channel and a plurality of spaced-apart fuel injector sockets connected with the fuel distribution channel. A high-pressure fuel pump has a high-pressure chamber connected internally to the fuel distribution channel without external high-pressure fuel lines.

Abstract: An ultra accurate gas injection system includes an input device for inputting setpoint data including a target flow rate for the flow of gas into the system. The gas flows through a mass flow controller at an actual flow rate. The mass flow controller issues a flow rate signal indicative of at least the actual flow rate and receives a flow control signal. The mass flow controller is configured to control the actual flow rate dependent at least in part upon the flow control signal. A programmable controller is electrically connected to the input device and the mass flow controller. The programmable controller receives the setpoint data from the input device and issues the flow control signal, the flow control signal being dependent at least in part upon the target flow rate contained within the setpoint data. The programmable controller repeatedly reads the flow rate signal and compares the actual flow rate with the target flow rate.

Abstract: A method and system for producing thin film alloy by a sputtering deposition process comprising using a crescent-shaped aperture interposed between the target and substrate of a sputtering deposition system.

Abstract: A variable valve train device for installation in an internal combustion engine to controllably vary the intake valve lift, open duration, and timing. A rotary camshaft has a cam lobe for rotation in timed relationship to the motion of the pistons of the engine. A close-fitting frame is rotationally disposed on the camshaft and is pivotably connected to a control shaft such that the angular orientation of the frame may be controlled with respect to the camshaft. A rocker arm disposed on the frame is provided with an input roller which follows the lobe of the camshaft to oscillate an output roller in response to rotary motion of the cam. The output roller drives an output cam which cooperates with a cam follower to open an engine intake valve conventionally against a valve spring. A curved return spring disposed between the output cam and the frame returns the output cam as the valve closes.

Abstract: A two stage exhaust gas recirculation (EGR) valve delivers a wide range of EGR flow while operating with reduced valve actuating forces allowing use of a reduced cost actuator such as a solenoid with smaller sized coil and armature. An attached valve body mounts concentric dual pintle valves including a larger first valve, which engages a valve seat in the valve body to control exhaust gas flow between inlet and outlet openings and a smaller second valve positioned inside the first valve and engaging a second valve seat in the head of the first valve. The second valve controls a low flow passage inside the first valve. The solenoid armature engages only the smaller second valve during a first stage of its stroke so that the smaller valve is opened first and flow control is maintained in a low flow range. Exhaust and intake differential pressures acting on the second valve are overcome by a smaller armature force because of the smaller area of the second valve.