Abstract: A steering system (10) has a rack housing (12) formed of a first tube (14) and a pinion housing (16) formed of a second tube (18). A first opening (31) is provided in the first tube (14) and a second opening (33) is formed in the second tube (18). The first opening (31) and second opening (33) expose a respective fillet (32), (34). The relative position of first opening (31) and second opening (33) determine the position of the first tube (14) with respect to the second tube (18). A first bushing (40) and a second bushing (42) are used to support a rack (36) within first tube (14). A pinion shaft (60) positioned within second tube (18) has a pinion gear (62) for coupling with rack (36). Preferably a first bracket (26) and second bracket (28) are positioned on first tube (14) adjacent to first bushing (40) and second bushing (42), respectively.

Abstract: An electrical machine such as an alternator (10) has a first housing (14) and a second housing (16) with a stator core assembly (18) therein. The stator core assembly has a plurality of windings (44) that are positioned within laminations (46). The windings have a first set of end turns (48), a second set of end turns (50), and winding ends 52. A respective first end cap (54) and a second end cap (56) are placed over respective end turns (48) (50). Potting material (58) is placed between the first end cap (54) and the first set of end turns (48) and the second end cap (56) and the second set of end turns (50). A stud assembly (60) having a stud housing (62) and a plurality of studs (64) is coupled to the first end cap. A bushing (68) is coupled to the studs (64) so that winding ends (52) may be coupled to a flat surface (70) thereof. The bushings (68) are also used to from an electrical connection between the rectifier bridge (36) and the stator core (42).

Abstract: There is disclosed herein a tri-metal-layer precircuit 50 which may be selectively etched to provide a multilayer electronic circuit 60 having air bridge crossovers 49. The enlarged ends 44 of the upper air bridge elements 42, and/or the top pads 41 of the tower elements 43, are specially designed such that undercutting of the ends 44 and/or top pads 41 is minimized, thereby minimizing the risk of air bridge/top pad delamination.

Abstract: An apparatus and method for connecting together first and second printed circuit boards 10/20 (PCBs), wherein one or both of the PCBs is a flex circuit. The method includes overlapping the two PCBs such that their respective matching circuit trace arrays 12/22 face each other and are separated by a small predetermined distance K, and then introducing molten solder 30 proximate an overlapping PCB edge 18, such as by wave soldering, so as to urge capillation of the molten solder between the two PCBs, thereby forming solder joints operatively connecting together the two circuit trace arrays.