Abstract: A fuel rail assembly includes a fuel injector socket having a cylindrical end for receiving an injector and a boxed end for orienting and positioning the injector relative to the engine cylinder. A boxed shape end cap is fitted over the boxed end of the socket thereby supporting the socket. Planar saddle members are disposed on each side of the end cap and radiused edges are fitted to the cylindrical surface of the fuel distribution tube. A jump tube communicates fuel from the fuel distribution tube to the fuel injector socket. A bracket defines a sole plate for the assembly, for attachment to an engine head, and includes a generally planar surface for locating against the planar surface of the saddle members. Components of the fuel rail assembly are first assembled loosely on a fixture, then joined together as the fuel rail assembly.

Abstract: A system for underfilling in a chip package includes an underfill mixture that ameliorates the CTE mismatch that typically exists between a packaged die and a resin-impregnated fiberglass mounting substrate. In one embodiment, the system includes an underfill mixture that comprises a principal underfill composition of a rigid octaaminophenyl silsesquioxane (OAPS) that is used as a curing agent for a tetrafunctional, low viscosity, and relatively rigid TGMX epoxy resin. An embodiment is also directed to the assembly of a flip chip package that uses the underfill mixture.

Abstract: An end cone assembly for an exhaust emission control device includes an inner cone spacedly disposed within an outer cone. The outer cone comprises a small outer cone end a large outer cone end and an outer wall that diverges from the small outer cone end to the large outer cone end. The inner cone comprises a small inner cone end and a large inner cone end with an inner wall having a first diameter proximal the first inner cone end, wherein the inner wall diverges to a second diameter, wherein the second diameter is disposed proximal a recessed portion having a third diameter at the second inner cone end, and wherein the first diameter is smaller than the third diameter and the third diameter is smaller than the second diameter. The outer wall is disposed in a spaced relation to at least a portion of the inner wall, and, with the exception of the recessed portion, the space between the inner and outer walls is free of insulating material.

Abstract: A solenoid-operated valve includes a valve body defining a valving bore for providing a path of communication between axially spaced inlet and outlet ports. A solenoid assembly is attached to the valve body and includes an inductor coil, a fixed flux guide and an armature, which is movable axially between a first position and a second position in response to electrical energization of the inductor coil. A valve member is disposed within the valving bore intermediate the inlet and outlet ports. An elongated control member interconnects the armature and the valve member for conjoined axial movement. A generally annular valve seat is disposed within the valving bore between the inlet port and valve member, the valve seat including a central through bore through which the control member extends.

Abstract: A method for providing supplemental internal air cooling to a multi-cylinder internal combustion engine. The method involves deactivating the fuel injector to one cylinder for a predetermined time period or temperature decrease, based upon engine operating conditions, and then reactivating the fuel injector. This results in cool air being pumped through the fuel-deactivated cylinder by the reciprocating action of the piston therein, which air-cools the walls, piston, and head of that cylinder from the inside. In response to a controlling algorithm in an Engine Control Module, various of the engine fuel injectors may be deactivated and then reactivated sequentially to provide distributed cooling over the entire engine. The invention is especially useful for motorcycle engines having two or more cylinders when the motorcycles are used at low or stop-and-go speeds, such as in parades or other ceremonial functions.

Abstract: A flow-through carbon adsorption device is provided with leads for imposing an electric current and with a temperature sensor at the desorption flow exit. The temperature sensor and electric current source are controlled by a controller. In adsorption mode, no current flows through the device. Hydrocarbons are adsorbed in the device before reaching atmosphere. In desorption mode, the temperature sensor and electric source are activated by the controller. Electric energy is converted to heat energy within the device. Air is drawn in reverse flow through the device. Because desorption is endothermic, the carbon bed becomes progressively cooler during desorption. When desorption is complete, the temperature of the device begins to rise and the controller shuts down the temperature probe and the electric heating system. Thus, full desorption of the device is assured without significant waste of electricity or compromise of subsequent adsorptive capacity of the device after desorption is complete.

Abstract: A method for improving the efficiency of a hydrocarbon catalytic reformer and close-coupled fuel cell system by recycling a percentage of the anode exhaust syngas directly into the reformer in a range between about 20% and about 60%. Oxygen is supplied to the reformer at start-up. Under equilibrium conditions, oxygen required for reforming of hydrocarbon fuel is derived entirely from endothermic reforming of water and carbon dioxide in the recycled syngas. Recycling of anode syngas into the reformer increases fuel efficiency, adds excess water to the reformate to increase protection against anode coking, and protects the fuel cell stack against air- and water-borne contaminants. A method for producing an excess amount of syngas for exporting for other purposes is also provided.

Abstract: A brushless DC motor and Hall Effect commutation sensors are mounted on a common circuit board, and ferromagnetic elements partially embedded in the motor stator in proximity to the periphery of the rotor magnetically couple the rotor magnet to the Hall Effect sensors. Preferably, the ferromagnetic elements are embedded in the stator adjacent the radial periphery of the rotor magnet. Alternately, the ferromagnetic elements can be embedded in the stator adjacent the axial periphery of the rotor magnet.

Abstract: A robust, easy to mount probe sensor includes an elongated body enclosing a sensor element and an integral flange extending away from the body. The body and flange are formed of material having a relatively low characteristic yield point. First and second generally parallel closely spaced through passages extend through the flange. An insert formed of material having a relatively high characteristic yield point is disposed in one of the passages. A fastener including a shank portion which extends through the other passageway includes an enlarged head which overlays the insert containing passageway and engages an attachment structure to effect directed compressive loading of the probe sensor flange.

Abstract: A fuel cell system in accordance with the invention includes a single, central electronic controller (CPU) for controlling at least the Air Handling sub-system, the Reformer sub-system, the Power Electronics sub-system, and the Customer Interface sub-system. The central controller provides a central location for easier serviceability; increases data transport efficiency by eliminating lengthy links between distributed controllers; eliminates the need for multiple mechanical enclosures; allows for controller thermo conditioning in one mechanical enclosure; and reduces parasitic power losses by employing a single power supply.

Abstract: Valve lift variation associated with a deactivation roller hydraulic valve DRVHL (DRHVL) can result in unacceptable valve overlap and idle conditions for an internal combustion engine. Two sources of length variation in a DRHVL are leakdown and residual mechanical lash. Total length variation is the sum of these two factors, and each factor has an associated tolerance. In the prior art, the two factors are independent, resulting in a total population variation that is the sum of the two independent variations. A DRHVL assembly process in accordance with the invention includes the step of associating leakdown test results for individual lash adjusters with residual lash results by adjusting the residual lash characteristics of individual DRHVL assemblies to complement the leakdown characteristics in minimizing total length variation in the population of assembled DRHVLs.

Abstract: An internally insulated exhaust aftertreatment device with a converter body, an end cone assembly and a sealing device inserted in an annular area between the external shell and the substrate of the converter body. The sealing device is sealingly engaged between an inner end cone and the insulating material. The sealing device comprises a wire-mesh ring-shaped device conformable to the annulus between the substrate and the shell, and may have a substantially round cross-sectional area, a C-shaped cross-sectional area, or an L-shaped cross-sectional area.

Abstract: A rotor-locking mechanism for a vane-type camshaft phaser. A locking pin is disposed in the rotor and is permitted to travel into a well in either the rear cover or the front cover of the phaser. The pin is urged into the well by a return spring, and the end of the pin end is exposed to oil pressure for unlocking the pin. A first channel is provided between the advance-oil feed and the end of the pin, and a second channel is provided between the retard-oil feed and the end of the pin. The channels may be formed in either of the covers. The pin is unlocked whenever a predetermined oil pressure is exceeded in either the advance or retard oil feeds, permitting the pin to be unlocked through most modes of engine operation and to be locked only under specific predetermined low-pressure conditions, such as during engine starting.

Abstract: In a multi-cylinder internal combustion engine having intake valve deactivation apparatus providing de-activation of the intake valves of selected cylinders during engine operation, correct cylinder activation status is verified by measuring gas pressure in a conduit conducting combustion related gases through the cylinders of the engine, detecting consecutive pulses in the pressure due to predetermined activations of the intake valves, comparing the time periods between the consecutive pulses to reference time periods based on crankshaft position and corresponding to expected time periods between the consecutive pulses and providing verification signals and cylinder identification of faulty intake valve deactivation or activation in response to the comparisons.

Abstract: A valvetrain system mechanization for an internal combustion engine using compression ignition, including homogeneous charge compression ignition, having two intake and one or more exhaust valves per cylinder. The valves are operated by dual overhead camshafts having two-step cams. The intake and exhaust camshafts are provided with phasers for varying the opening and closing of the intake and exhaust valves. A two-step roller finger follower is disposed for each valve between the cam lobes and the valve stem. The two sets of intake and exhaust valves are controlled by separate oil control valves. Swirl of gases may be introduced by mismatching the lifts of the valves. The valve opening times, closing times, lifts, fuel injection, compression ratio, and exhaust gas recirculation may be varied to optimize combustion conditions for a range of engine operating modes.

Abstract: A twin spark ignition apparatus having two high-voltage (HV) outputs incorporates features for balancing load capacitance on each HV output. The ignition apparatus provides a first high-voltage (HV) connection configured for direct mounting on a first spark plug, and a second HV connection for coupling to a second spark plug by way of an HV cable. The HV cable would adds capacitance at the second HV output, as compared to a direct mount. Various structures are included to offset and balance the additional capacitance attributable to the HV cable so that the capacitance of the first HV connection and the second HV connection are balanced within a range. The voltage variation between the two HV outputs is reduced.

Abstract: A deactivation valve lifter includes a lifter body. The lifter body has a first end configured for engaging a cam of an engine and at least one annular pin chamber. A pin housing includes a pin housing bottom. The pin housing bottom defines at least one pin stop aperture and a radially directed pin bore. A deactivation pin assembly is disposed within the pin bore and includes pin members. The pin housing is concentrically disposed within the lifter body. A portion of each pin member may be disposed within the annular pin chamber to thereby selectively couple and decouple the lifter body to the pin housing. A drain aperture defined by the pin housing bottom extends from the pin bore to an outside surface of the pin housing. A stop pin is disposed in the at least one pin stop aperture for limiting the inward motion of the pin members.

Abstract: A target wheel for a camshaft phaser stamped and drawn from sheet metal stock. The hub region of the target wheel may be drawn such that it extends through the phaser cover plate and seals directly against the face of the rotor, allowing a shorter cam bolt and resulting in reduction in mass and cost of the phaser. Alternatively, a separate hub is formed and then attached to a simplified stamped and drawn target wheel, or a target wheel hub is formed integrally with the rotor and extends through the cover plate to mate with a simplified stamped and drawn target wheel. Preferably, the hub is formed having a neck extending through a central opening in the target wheel, which neck is peened over during assembly to secure the wheel to the hub.

Abstract: A method for distributing lock pin ejections evenly over all the switchable mechanisms in a plurality of switchable mechanisms: establishing a limiting number of lock pin ejections; designating a primary switchable mechanism for the mode change upon command from an engine control module (ECM); employing the designated primary switchable mechanism until the limit is reached; designating another switchable mechanism a primary; employing the second primary mechanism until the limit is reached again; and designating sequentially each of the remaining switchable mechanisms as primary switchable mechanisms, each until the limit is reached again. The ECM counts the activation commands and switches the primary designation when the limit is reached so that each mechanism has the same exposure to ejections, and the number of ejections per mechanism is evenly distributed.

Abstract: The piezoelectric element of an engine knock sensor is held between upper and lower ring-shaped bases by two identical clips that extend through the piezoelectric element and engage each base. Each clip has a ring-shaped flange engaging a groove circumscribing the inner wall of one of the bases, with the flanges of the clips engaging opposite bases. Also, each clip has three legs that engage a groove in the opposite base. Each clip leg is disposed between two legs of the other clip.